Westfalia Separator AGMechanical Separation Division Instruction Manual No.: 2325-9001-020 Edition: 0806 2 Westfalia Separator AG © All rights reserved. No part of this document may be reproduced in any form – by graphic, electronic or me- chanical means including all types of photocopying or any other means of duplication – without our prior written consent. The transmission of originals and reproductions to third parties is prohibited without our prior consent. 2325-9001-020 / 0806 Westfalia Separator AG 3 1 Introduction 7 1.1 About this manual ....................................................................................9 1.2 It is imperative to observe the following instructions to assure safe operation of the separator......................................................................10 1.3 For your safety.......................................................................................12 1.4 Note on the symbols used in the documentation ..................................13 1.5 Old symbols: ..........................................................................................13 2 Lubrication 17 2.1 Lubricating system.................................................................................18 2.1.1 Oil quality ...............................................................................................19 2.1.2 Oil quantity.............................................................................................19 2.1.3 Oil change..............................................................................................19 2.2 Bowl parts ..............................................................................................20 2.3 Motor bearings.......................................................................................20 3 Motor connection 21 3.1 Three-phase AC motor ..........................................................................22 3.2 Direction of rotation of the bowl .............................................................25 3.3 Bowl speed ............................................................................................25 3.4 Starting time of the bowl ........................................................................26 3.5 Run-down time of the bowl ....................................................................26 3.6 Speed measuring device .......................................................................27 3.7 Electronic vibration monitoring ..............................................................27 4 Bowl 29 4.1 Important hints .......................................................................................30 4.1.1 Special risks of a separator ...................................................................31 4.1.2 Safety precautions for maintenance and repair..................................... 34 4.2 Removing the feed and discharge connections .................................... 39 4.3 Dismantling the bowl..............................................................................42 4.4 Assembling the bowl..............................................................................48 4.4.1 Fitting the centripetal pump ................................................................... 55 4.4.2 Installing the swivel-type actuator..........................................................57 4.5 Assembling the feed and discharge connections .................................. 58 4.6 Replacing the main bowl gasket (bowl top) ...........................................60 4.7 Bowl valves............................................................................................61 4.8 Disk stack compressing device .............................................................63 5 Technical information 65 5.1 Constructional features.......................................................................... 66 5.2 Operating principles of the bowl ............................................................ 68 5.3 Operating principles of the hydraulic system of the bowl ...................... 70 5.3.1 Bowl ejection..........................................................................................71 2325-9001-020 / 0806 4 Westfalia Separator AG 5.4 Operating water connection...................................................................72 5.4.1 Solenoid valves......................................................................................73 5.5 Swivel-type actuator for control of the centripetal pump ....................... 73 6 Operation 75 6.1 Before start-up ....................................................................................... 76 6.2 Start-up ..................................................................................................77 6.3 Closing of bowl: .....................................................................................77 6.4 Water run after start-up..........................................................................78 6.4.1 Program control .....................................................................................78 6.4.2 Function diagram of partial ejection.......................................................81 6.4.3 Total ejection .........................................................................................82 6.4.4 Bowl ejection (manual) ..........................................................................82 6.5 Adjusting the separation efficiency ........................................................83 6.5.1 Adjusting the "Fine Tuner" .....................................................................83 6.5.2 Calculation of the "Fine Tuner" diameter...............................................84 6.5.3 Presetting separation.............................................................................84 6.5.4 Adjusting the hydrohermetic feed ..........................................................85 6.5.5 Final adjustment of separating efficiency ..............................................86 6.6 Product mode ........................................................................................86 6.7 Shut-down (Normal Off).........................................................................88 6.8 Shut-down (Emergency-Off) ..................................................................88 6.9 Run-down (overspeed) ..........................................................................89 6.10 After shut-down......................................................................................89 6.11 Prior to a long-term shut-down .............................................................. 89 6.12 Trouble shooting ....................................................................................90 7 Cleaning 95 7.1 Cleaning-in-place...................................................................................96 7.2 Bowl .......................................................................................................99 7.3 Frame...................................................................................................100 7.4 Operating water feeding device...........................................................100 7.5 Cleaning the lube-oil vessel .....................................................................100 7.6 Prior to a long-term shut-down ............................................................101 7.7 Note on cleaning work on hoods .........................................................102 7.8 Note on cleaning work on disks...........................................................102 8 Drive 103 8.1 Drive.....................................................................................................104 8.1.1 Special risks of a separator .................................................................105 8.1.2 Safety precautions for maintenance and repair...................................108 8.2 Fitting and removing the motor............................................................112 8.2.1 Removing the motor ............................................................................112 8.2.2 Installing the motor ..............................................................................113 8.3 Removing spindle assembly, supporting disk......................................114 8.4 Dismantling the spindle assembly .......................................................116 8.5 Assembling the spindle unit .................................................................118 8.6 Replacing the rubber-metal bushes and the rubber cushions.............121 8.7 Installing the spindle assembly............................................................123 8.8 Adjusting the proximity switch .............................................................124 2325-9001-020 / 0806 Westfalia Separator AG 5 9 Trouble shooting 125 9.1 Mechanical function .............................................................................126 9.2 Clarifying function ................................................................................130 10 Lubrication and maintenance 135 10.1 Lubrication schedule............................................................................136 10.2 Maintenance schedule.........................................................................137 10.2.1 Guide to ordering spare parts..............................................................138 10.2.2 Use of non-genuine spare parts ..........................................................139 2325-9001-020 / 0806 6 Westfalia Separator AG 2325-9001-020 / 0806 Westfalia Separator AG 7 1 Introduction 1.1 About this manual ....................................................................................9 1.2 It is imperative to observe the following instructions to assure safe operation of the separator......................................................................10 1.3 For your safety.......................................................................................12 1.4 Note on the symbols used in the documentation ..................................13 1.5 Old symbols: ..........................................................................................13 2325-9001-020 / 0806 8 Westfalia Separator AG Note Notes Notizen Anotaciones Notizen Notes Note 2325-9001-020 / 0806 Westfalia Separator AG 9 1.1 About this manual This manual is part of the documentation supplied with the separator. Everyone who works with or on this machine must have read and understood this manual and also the brochure “Safety precautions for separators”. In order to make available to you the latest safety precautions, they have been set out in a separate brochure “Safety precautions for separators”. They reflect the state of the art and are furnished with the separator documenta- tion. In the interest of your personal safety and a better understanding of the machine, please first read the brochure “Safety precautions for separa- Safety precautions tors” and then this manual. This booklet must be kept for further use and be available at all times in the vicinity of the separator for all persons who work with or on the sepa- rator. NOTE The documentation contains important information for all persons who work with or on the separator. Non-compliance with the instructions in the documentation can not only result in danger for machines, material and Caution environment but also endanger persons who work on or in the environ- ment of the separator. (danger to life, risk of injury) At the beginning of this manual, you will find the schematic of the separa- tor and the nameplate. The nameplate must be filled in by the operator. Enter the data from the nameplate on the separator. Dangers of later con- NOTE fusion are thus avoided. If this machine is used in an explosion-hazarded zone, please first read the brochure “Separators in explosion-hazarded areas” and then this manual in the interest of your own safety and for better understanding of NOTE the machine. 2325-9001-020 / 0806 10 Westfalia Separator AG 1.2 It is imperative to observe the following instructions to assure safe operation of the separator. 1. Assign only adequately trained and competent personnel with operation, maintenance and repair of the separator. 2. Before every start-up, ensure that all parts are fitted, completely mounted and that all connections on and around the separator are secure and tight. 3. Never use the separator for a purpose other than the intended and correct purpose! 4. Never operate the separator at a speed higher than that specified on the nameplate (rating plate)! 5. Never ignore or acknowledge an alarm without first eliminating the cause! 6. Never start-up or shut-down a partially filled bowl. Danger of imbalance! 7. Never loosen any part before the separator has come to a complete standstill. Before carrying out maintenance and repair work, switch off the separator, wait until it has come to standstill and check that all rotating parts have really come to rest. Then switch off the main switch and lock the machine to prevent it from accidentally being switched back on. 8. When unusual noises and / or vibrations occur, shut down the separator via “Emergency Off” and evacuate the room. Never perform an ejection! 9. Never heat the bowl and bowl parts with a naked flame during dismantling! Welding on the bowl and bowl parts are likewise strictly prohibited. 10. Shut down the separator immediately when damage caused by corrosion or erosion is detected on the bowl. 11. The hood and solids catchers of steam-sterilizable separators are pressure vessels. It is prohibited to weld or machine them! 12. Adjust the disk pressure as specified in the documentation. An incorrect disk pressure can lead to severe imbalance. 13. Have the separator checked by competent, qualified personnel at least once a year in operating state and at least every 3 years in dismantled state. 14. Do not carry out conversions or modifications to the separator. 15. When working on the separator or with dangerous operating materials, al- ways wear the necessary protective gear. 16. Operating the separator with hot products leads to hot surfaces of hood, sol- ids catcher and surrounding piping. Danger of burns! 2325-9001-020 / 0806 Westfalia Separator AG 11 17. Always flush the separator after chemical cleaning (CIP). 18. Regularly check the separator, paying particular attention to its nozzles and ejection system to avoid malfunctions. Where necessary, regularly check con- centrate nozzles for damage to nozzle stones and soldered joints. Replace damaged nozzles immediately! 19. Use only genuine spare parts from Westfalia Separator. 20. Ensure that the personnel has access to the documentation and that, in par- ticular the safety precautions and instructions have been read and understood before commissioning and working on the separator. 2325-9001-020 / 0806 12 Westfalia Separator AG 1.3 For your safety Observe accident prevention regulations. The local safety and accident prevention regulations apply uncondi- tionally to the operation of the separator. Refer to the documentation supplied. Proceed only in accordance with the documentation supplied. Operate the separator only in accordance with agreed process and operating parameters. Maintain the separator as described in the documentation supplied. Carry out safety checks on the separator, as described in the documentation supplied. Liability for the function of the machine passes to the owner. Liability for the function of the machine passes unconditionally to the owner or operator irrespective of existing warranty periods in so far as the machine is improperly maintained or serviced by persons other than Westfalia Separator personnel or if the machine is not ap- plied in accordance with the intended use. Westfalia Separator AG shall not be liable for damage which occurs as a result of non-compliance with the above. Warranty and liability conditions in the Conditions of Sale and Delivery of Westfalia Sepa- rator AG are not extended by the above. 2325-9001-020 / 0806 Westfalia Separator AG 13 1.4 Note on the symbols used in the documentation Below is an explanation of the meaning of the symbols used in the documenta- tion. Special attention must be paid to all passages in the documentation marked with safety symbols. The operation described after such a symbol must be car- ried out with utmost care. This symbol indicates potential danger to persons. (danger to life, risk of injury) Caution This symbol indicates potential risks for machine, material and environ- ment. Attention! This symbol draws attention to the fact that at this point additional manu- als must be read and observed. Instruction manual This symbol does not indicate safety precautions but rather information for a better understanding of the machine. NOTE 1.5 Old symbols: Strictly adhere to instructions marked with this symbol. This avoids damage or destruction of the separator and other equip- ment. Take special care when carrying out operations marked with this symbol otherwise danger to life. 2325-9001-020 / 0806 14 Westfalia Separator AG Note Notes Notizen Anotaciones Notizen Notes Note 2325-9001-020 / 0806 Westfalia Separator AG 15 Westfalia Separator …………….GmbH D-59302 Oelde ( Germany) Type Serial-No. Model Max. admissible rated bowl speed in min-1 Max. admissible density in kg/dm3 of product Heavy liquid kg/dm3 Solids kg/dm3 min/max throughput m3/h min./max. temperature of product in °C min/max housing pressure range in bar 2325-9001-020 / 0806 16 Westfalia Separator AG Note Notes Notizen Anotaciones Notizen Notes Note 2325-9001-020 / 0806 Westfalia Separator AG 17 2 Lubrication 2.1 Lubricating system.................................................................................18 2.1.1 Oil quality ...............................................................................................19 2.1.2 Oil quantity.............................................................................................19 2.1.3 Oil change..............................................................................................19 2.2 Bowl parts ..............................................................................................20 2.3 Motor bearings.......................................................................................20 2325-9001-020 / 0806 18 Westfalia Separator AG 2.1 Lubricating system 1 Fig. 1 1 External oil lubrication unit The drive bearings are supplied with oil by the oil circulation lubrication system (external oil lubrication unit). The oil feed is under pressure, the lube oil return is under gravity or under pressure, as illustrated above. For the electrical connection of the external oil lubrication unit, bear in mind that it has to be switched on when the separator reaches a certain bowl speed dur- ing start up and that it must be switched off during shut-down. The specific bowl speeds are listed in the datasheet. NOTE For more in-depth information concerning the external oil lubrication unit, refer to the instruction manual supplied with the oil lubication unit. Instruction manual 2325-9001-020 / 0806 Westfalia Separator AG 19 2.1.1 Oil quality As lube oil use only gear oils with the WS part number stated in the parts list or on the data sheet. Do NOT use motor vehicle gearbox or engine oils. NOTE 2.1.2 Oil quantity Before starting the separator for the first time fill the oil vessel of the exter- nal oil lubrication unit with oil until the oil level reaches the upper mark of the oil level indicator. Minimum oil level: slightly above the lower mark of the oil level indicator Maximum oil level: slightly below the upper mark of the oil level indicator Fig. 2 During operation, the oil level in the vessel of the oil lubrication unit must never be below minimum level; do not fail to re-fill in time (see chapter “Lubrication and maintenance”, section “Maintenance schedule”). IMPORTANT The quantity of oil needed for filling the vessel is indicated in the instruction manual of the oil lubrication unit. NOTE 2.1.3 Oil change The operating hours up to the first oil change and the subsequent oil change intervals are specified in the “Maintenance Schedule”. Change the oil at the latest as specified in the “maintenance schedule” even if the operating hours specified for an oil change have not been reached. NOTE Whenever changing the oil, clean the lubricating oil chamber thoroughly with thin-bodied oil. Do not use fluffy cleaning rags or cotton waste! Clean sight glass. 2325-9001-020 / 0806 20 Westfalia Separator AG 2.2 Bowl parts Before assembling the bowl, coat the threads, guide and contact surfaces on bowl parts such as: – Bowl bottom, – sliding piston, – bowl top, – lock rings, etc. with the lubricating pastes or greases specified in the parts list. Use only lubricants tested by Westfalia Separator for use on separators. The use of non-genuine parts leads to: – safety risks, – less durability of these parts, – reduced availability of the separator, NOTE – increased maintenance requirement. In this case, Westfalia Separator shall assume no liability or warranty. During assembly, note: Do not bring gaskets made from the special material EPDM (ethylene- propylene-diene-caoutchouc) in contact with mineral oils and greases. Consequence in the event of contact: Swelling of the gaskets Attention! EPDM-compatible silicon greases can be used for these gaskets to facilitate assembly. The greased surfaces must be free from sand and filings. Otherwise the sur- faces can become scored. When cleaning, check the threads, contact and guide surfaces for impact marks. Impact marks will result in scoring. 2.3 Motor bearings For lubrication of the motor bearings, refer to the instructions of the manufacturer (see motor plate). Instruction manual 2325-9001-020 / 0806 Westfalia Separator AG 21 3 Motor connection 3.1 Three-phase AC motor ..........................................................................22 3.2 Direction of rotation of the bowl .............................................................25 3.3 Bowl speed ............................................................................................25 3.4 Starting time of the bowl ........................................................................26 3.5 Run-down time of the bowl ....................................................................26 3.6 Speed measuring device .......................................................................27 3.7 Electronic vibration monitoring ..............................................................27 2325-9001-020 / 0806 22 Westfalia Separator AG 3.1 Three-phase AC motor All separators are driven by three-phase motors. Depending on the construction, the following drive variants are available: Direct drive – with frequency converter Gear drive – with fluid or centrifugal clutch – with frequency converter Belt drive – with controlled torque motor – with frequency converter – with clutch The technical specifications on the motor supplied are given in the data- sheets supplied with the documentation, the motor nameplate and / or the documentation of the motor manufacturer. NOTE The switching devices must be rated for the starting current of the motor. Starting currents Depending on the different drive and motor types, different starting currents are required for starting a separator. – with frequency converter approx. rated current – with fluid or centrifugal clutch approx. 1.5 – 2 times rated current – with controlled torque approx. 2 – 3 times rated current Motor protection If the motor is equipped with a PTC thermistor, it must be connected to the corresponding tripping device. Lay the measuring circuit line (tripping device-motor) as a separate control line. Lubrication If the motor is equipped with a re-lubricating device, it must be re- lubricated at regular intervals in accordance with the specifications of the Attention! motor manufacturer on the motor nameplate. 2325-9001-020 / 0806 Westfalia Separator AG 23 Motor with frequency converter (FC) Pay attention to the following when operating the separator with frequency con- verter: The separator must never be started without frequency converter. Attention! The frequency on the frequency converter must be selected so that the maximum admissible bowl speed is not exceeded. The admissible bowl speed is indicated on the nameplate of the separator. The frequency converter is equipped with a frequency limiter to prevent the admissible bowl speed from being exceeded. Additionally, a speed sensor is installed on the separator. The latter transmits the pulses for bowl speed monitoring to the control system. The control system switches off the separator when the ceiling speed is ex- ceeded. NOTE The separator may be operated only with this auxiliary device. The ceiling speed must be set to 5% above rated speed (see separator nameplate). Important measures to take during commissioning: Check the correct setting of the monitoring devices in accordance with the cir- cuit diagram and setting instructions. Check the speed of the drive spindle. Test the safety circuit. Attach the following safety stickers and check that they are properly attached and in good condition. 2325-9001-020 / 0806 24 Westfalia Separator AG Frequency converter operation The admissible maximum bowl speed must not be exceeded. Fig. 3 Before carrying out maintenance or repair work on the motor, bear in mind that there may still be residual voltage. CAUTION! In this connection, refer to the documentation of the frequency converter manu- facturer and have safety measures implemented by suitable personnel. 2325-9001-020 / 0806 Westfalia Separator AG 25 3.2 Direction of rotation of the bowl The bowl must rotate in clockwise direction when looked at from above. CAUTION! If the direction of rotation is wrong, the wiring of the motor power supply lead must be checked for conformity with the circuit diagram and changed accord- ingly. This may only be carried out by an authorized specialist. 3.3 Bowl speed The bowl speed has been defined to suit the process as a function of the densi- ties of the centrifugally dry solids and the clarified liquid. All components have been constructionally rated for this speed (operating speed) taking into account all safety-relevant factors. The operating speed (bowl speed) and other important process data are speci- fied on the separator nameplate. Alterations to the process data may also ne- cessitate a change in operating speed. The bowl speed may not be changed by the operator without appropriate consultation. The bowl speed stated on the separator nameplate must not be exceeded! The manufacturer must be contacted before changing process data. CAUTION! If this instruction is not observed, there is danger to life and limb of the persons working on the separator by machine parts flying around. Always check the spindle speed when drive parts have been re- placed. Also pay attention to the direction of rotation of the spindle and bowl. It must rotate clockwise (see arrow on frame). If this is not the case, an electrician must alter the connection at the motor. Fig. 4 The spindle speed must be checked before the first start-up and before fitting the bowl. NOTE 2325-9001-020 / 0806 26 Westfalia Separator AG 3.4 Starting time of the bowl Specifications on the starting time of the bowl are given in the enclosed data sheets. NOTE Make sure that the bowl reaches its rated speed within the starting time and that this speed is maintained during operation. Separators with a motor controlled by frequency converter can be re-started any time. The following applies for separators with controlled torque motors: Re-starting after the motor has reached a constant operating temperature is permitted only after 60 minutes. IMPORTANT Non-observance of this instruction can lead to overheating of the clutch or mo- tor. 3.5 Run-down time of the bowl The run-down time of the separator bowl, from switching off to shutdown, is specified in the data sheet. The run-down time specified in the data sheet refers to the rated speed (see separator nameplate) with free run-down and at atmospheric pressure. NOTE In addition to mechanical or electric brakes, the run-down time of the separator can be influenced by various process factors. The run-down time specified in the data sheet specifies the maximum time span required until the separator bowl has stopped rotating. After the run-down time and before working on the separator: Check that the separator is at a standstill. Otherwise, there is a danger of injury through rotating bowl parts or dis- CAUTION! charging liquids. Pay attention to the safety precautions relating to “checking standstill”. 2325-9001-020 / 0806 Westfalia Separator AG 27 3.6 Speed measuring device When the separator is equipped with a speed measuring device, detailed expla- nations are given in the documentation furnished with the separator control. 3.7 Electronic vibration monitoring Electronic vibration monitoring systems protect the separator against inadmis- sibly high vibration levels. If certain preset limit values are exceeded, an alarm is given and follow-up measures are initiated. Vibration monitoring of the bowl spindle On some separators, a further proximity switch for additional vibration monitor- ing of the bowl spindle is fitted. When bowl imbalance occurs (= vibratory motion of the spindle), this information is transmitted to a downstream evaluating unit and/or indicator and the necessary follow-up measures are initiated. 2325-9001-020 / 0806 28 Westfalia Separator AG Note Notes Notizen Anotaciones Notizen Notes Note 2325-9001-020 / 0806 Westfalia Separator AG 29 4 Bowl 4.1 Important hints .......................................................................................30 4.1.1 Special risks of a separator ...................................................................31 4.1.2 Safety precautions for maintenance and repair..................................... 34 4.2 Removing the feed and discharge connections .................................... 39 4.3 Dismantling the bowl..............................................................................42 4.4 Assembling the bowl..............................................................................48 4.4.1 Fitting the centripetal pump ................................................................... 55 4.4.2 Installing the swivel-type actuator..........................................................57 4.5 Assembling the feed and discharge connections .................................. 58 4.6 Replacing the main bowl gasket (bowl top) ...........................................60 4.7 Bowl valves............................................................................................61 4.8 Disk stack compressing device .............................................................63 2325-9001-020 / 0806 30 Westfalia Separator AG 4.1 Important hints The separator bowl rotates at a very high speed. Hence, forces are produced which can endanger the operating safety of the machine in case of – incorrect assembly or – inadequate cleaning of the bowl. The instructions for assembly must therefore be followed exactly. The following points should also be observed: Before fitting the bowl parts thoroughly clean, grease or lubricate: Attention! – Guide and contact surfaces – Lock ring When fitting the bowl parts, make sure that the "O" marks on all parts are in line with each other. (Only then will the parts fit correctly over arresting pins and guide ribs). Avoid damage to bowl parts during assembly and dismantling by – exact positioning. – avoiding diagonal pull. – selecting the lower lifting speed of the hoist. Only use correctly rated, fully functional hoists. Do not use force to fit or remove parts. Caution Before fitting gaskets, check the gaskets and gasket grooves for cleanness and wear. After fitting, check that the gaskets – are not twisted. – fit evenly into their grooves. All bowl parts – must be handled gently – and placed on a rubber mat or wooden pallet. In the case of a plant with several separators: Do not interchange parts of different bowls (danger of imbalance). Caution The bowl parts are marked with the serial number of the machine or the last three digits of the serial number. 2325-9001-020 / 0806 Westfalia Separator AG 31 4.1.1 Special risks of a separator The separator is equipped with a high-speed rotating metal bowl which repre- sents a danger potential not to be underestimated on account of the rotational energy which can pose a danger for the installation and persons working in the installation when not properly handled. Switch off the separator before carrying out maintenance or repair work. Wait, observe and check that all rotating parts are at a standstill. Do not reach into the rotating drive section or bowl! Do not loosen any part before the bowl has come to a standstill! CAUTION! Risk of injury and danger to life through rotating parts. Standstill should not be checked using only one source of information (e.g. speed indicator) but must be backed up by at least one further checking device. It must always be reckoned with that the first used standstill indication will pro- vide false information because, for example, the electronics have failed or the belt or gearbox in the drive is defective. The following options are available for checking standstill on separators depend- ing on the version: Electric speed indicator Revolution indicator or sight glass on the gear cover of gear separators Optical speed check of the drive motor Noise check Vibration check If you are not sure whether the machine is at a standstill, you must wait for the run-down time specified in the separator documentation. A subsequent check is carried out when you are sure that the machine is at a standstill. Visual speed check by opening the inspection ports on hood and frame Removing the inspection port in the separator hood enables you to look directly on to the bowl. In addition, checking is also possible by removing the gearbox cover or opening the port in the frame. Only when you are convinced that the separator is at a standstill can the following checks be carried out for additional security. NOTE 2325-9001-020 / 0806 32 Westfalia Separator AG Revolution visual check on ma- chines with belt drive. You can observe whether the machine is at a standstill at the points marked with the arrows. We reserve the right to carry out de- sign modifications. Fig. 5 Revolution visual check on ma- chines with gearbox. You can observe whether the machine is at a standstill at the points marked with the arrows. We reserve the right to carry out de- sign modifications. Fig. 6 Revolution visual check on ma- chines with direct drive. You can observe whether the machine is at a standstill at the points marked with the arrows. We reserve the right to carry out de- sign modifications. Fig. 7 2325-9001-020 / 0806 Westfalia Separator AG 33 Observing the motor fan is not a reliable method of checking standstill because the motor or fan can already be at a standstill when the separator bowl is still rotating. NOTE During cleaning programs (steam sterilization and CIP), very high temperatures are reached on the surfaces of the separator and piping. During cleaning programs, the surfaces of the separator and pipes are very hot. CAUTION! Danger of burns! With some products, the separator has to be cooled. As a result, temperatures of up to minus 30 °C are reached on the surfaces of the separator and pipes. When the cooling is switched on, the surfaces of the separator and pipes can get very cold. CAUTION! Danger of frostbite! Depending on type and installation site, hazards in the form of noise emission from the separator may occur. Therefore, always wear protective gear in accordance with the national regulations. CAUTION! Danger of hearing damage! During all maintenance and repair work on the separator, the fittings and pipelines, there is the risk of injury due to spurting liquids, e.g. hot or caustic liquids can spurt out under pressure. CAUTION! Danger of causticization of skin and eyes! 2325-9001-020 / 0806 34 Westfalia Separator AG 4.1.2 Safety precautions for maintenance and repair Observing the maintenance intervals and user information is decisive for the service life and permanent operating readiness of the separator. The maintenance intervals depend on the operating conditions. Especially highly stressed parts of the separator must be regularly checked. Reduce the maintenance intervals to adapt to the operating conditions! Timely maintenance of the separator is essential for safe operation. Especially highly stressed parts of the separator such as – Bowl lock ring, – Bowl bottom, – Bowl top must be regularly checked (at least once a year) as specified in the main- tenance schedule to assure safe and efficient operation. Fig. 8 When carrying out maintenance and repair work: Do not climb onto or stand on the machine or parts of the machine! Danger of injury through slipping or falling down! Fig. 9 Repairs to the separator may only be carried out by service technicians from Westfalia Separator or personnel trained and certified by Westfalia Separator. 2325-9001-020 / 0806 Westfalia Separator AG 35 During maintenance and repair work, make sure that the main switches are switched off and se- cured against restarting. Make sure that other persons do not have the possibility to start the ma- chine before the maintenance or re- pair work is finished. Fig. 10 Make sure that the rotating parts of the separator (drive, bowl) are at a stand- still before carrying out maintenance and repair work. When the machine is defective, a warning sign must be attached and the separator must be secured against unauthorized starting. Do not heat bowl parts with a naked flame to facilitate disman- tling work. Structural changes in the material of the bowl parts which affect the operat- ing safety of the machine may result! Do not weld bowl parts. Fig. 11 Do not weld hood and solids catcher parts of steam-sterilizable separators. 2325-9001-020 / 0806 36 Westfalia Separator AG Place the dismantled separator parts on suitable surfaces (rubber, wood etc.). Take appropriate steps to prevent machine parts from overturning and rolling away. Fig. 12 When carrying out assembly work on several separators, be careful not to interchange parts of different bowls! Each bowl must be balanced with its respective components. The parts are marked with the serial- number of the machine or with the last three digits of the serial number. Fig. 13 Some bowl parts must be arranged in fixed positions relative to one an- other. Locking devices and alignment marks must be in perfect condition. The separator may not be operated when locking devices and marks on the bowl parts are damaged. Fig. 14 2325-9001-020 / 0806 Westfalia Separator AG 37 After fitting certain new bowl parts (e.g. bowl bottom, bowl top) the bowl must be re-balanced. Bowl balancing may be carried out only by specialists from Westfalia Separator or specialist workshops authorized by Westfalia Separator! If in doubt, consult the service de- partment of Westfalia Separator. Fig. 15 Unqualified balancing can lead to dangerous operating states and to de- struction of the separator with danger to life and limb of the personnel. CAUTION! Do not manipulate speed-altering devices such as frequency converters so that the maximum admissible bowl speed (see nameplate or “technical data” in the instruction manual) is not exceeded. Ensure that monitoring devices (e.g. overspeed monitors etc.) are not ma- nipulated or damaged and check their function in accordance with the instruc- tions in chapter “Maintenance and repair – maintenance schedule”. After maintenance and repair work on the separator, refit all protective de- vices. When carrying out maintenance and repair work, carry out a visual check of the separator components. Have the components checked for damage through corrosion and erosion by authorized specialists and proceed in accordance with the instructions in chapter “Maintenance and repair – in- spections”. 2325-9001-020 / 0806 38 Westfalia Separator AG Lock ring Gasket Centripetal pump Chamber cover Separating disk Centripetal pump Chamber cover Gasket Gasket Upper centripe- tal pump Distance sleeve Centripetal pump Gasket Chamber cover Gasket Disk Gasket Centripetal pump Chamber cover Gasket Gasket Distance sleeve Gasket Distributor Sleeve Lower distributor Feed tube Gasket Spindle screw Sliding piston Gasket Gasket * Lock ring Gasket Gasket * Bowl top Bowl bottom Gasket Gasket Fig. 16 *) Attention: After replacing this part, the complete bowl must be re-balanced! 2325-9001-020 / 0806 Westfalia Separator AG 39 4.2 Removing the feed and discharge connections Switch off and lock the main switch. Caution! To prevent accidents, do NOT loosen any part before the bowl has stopped completely! Caution Standstill of the bowl is indicated by – LED "bowl standstill" or – the speed indicator in the control unit or in the motor control or – revolution indicator or – gear standstill, visible through the sight glass on the frame. Replace worn gaskets immediately. For tools, see separate order-specific parts list. Stop compressed-air supply. Disconnect electrical connection 1 and compressed-air supply 2. Note: This has to be done before remov- ing the guards - danger of crush- ing! Caution Fig. 17 Disconnect the following lines: – Cooling lines of the hood cooling, – flush water line, – supply line to hood flushing. Disconnect the feed and discharge lines. Cut off the electrical connection to the contact pressure gauge and sight glass illumination. Unscrew vent line 2. Unscrew connection piece 1. Lift off the connection housing. Fig. 18 2325-9001-020 / 0806 40 Westfalia Separator AG Unscrew hex head screws 3. Remove protecting-case halves 1 and 2. Fig. 19 Remove toothed segment 3. Fig. 20 Unscrew hexagon nuts 5. Thread two eye bolts 1 into the ta- pholes. Lift off ring 2 together with swivel- type actuator. For the transport, use lifting device, if required (correct ap- plication is shown on (Fig. 23 ). Fig. 21 Screw two ring nuts opposite each other onto the studs of the hood. Fig. 22 2325-9001-020 / 0806 Westfalia Separator AG 41 Unscrew the screws for fastening the hood. Shorten the chains of the lifting de- vice. Hang the shortened lifting device into the lifting-eye nuts and lift off the hood. Fig. 23 2325-9001-020 / 0806 42 Westfalia Separator AG 4.3 Dismantling the bowl Unscrew centripetal pump chamber lock ring by lightly hammering against the handle of the annular wrench (left-hand thread). Lift off the centripetal pump lock ring. Fig. 24 Lift off centripetal pump chamber cover using lifting tongs 1. Fig. 25 Remove cover 1. Fig. 26 Pull off the distance sleeve 1 with upper centripetal pump. Fig. 27 2325-9001-020 / 0806 Westfalia Separator AG 43 Remove upper centripetal pump 1. Fig. 28 Lift off centripetal pump chamber cover 1. Fig. 29 Pull off lower centripetal pump 1. Fig. 30 Force off centripetal pump chamber cover 1 by screwing in hex head screws 2. Lift off centripetal pump chamber cover 1. Unscrew hex head screws 2. Pull off disk 3. Fig. 31 2325-9001-020 / 0806 44 Westfalia Separator AG Lift out feed tube 1 with lower dis- tributor 2. Fig. 32 Unscrew spindle screw with the wrench (left-hand thread). Fig. 33 2325-9001-020 / 0806 Westfalia Separator AG 45 Mounting the compressing device: Screw threaded rod 1 as far as it will go into the bowl bottom (left-hand thread). Insert hydraulic part 3 into the cen- tering recess of the disc 4. Screw on threaded ring 2 until its upper edge is flush with end thread of bolt 1 (left-hand thread). Fig. 34 To prevent damage to threads: Screw in threaded bolt completely. Attention! Screw on threaded ring down to thread end. If the threaded ring cannot be screwed down completely, then the piston and the cylinder of the compressing device are too far apart. In this case: Bring piston and cylinder into initial position: – Loosen pressure relief screw 5 by two turns. – Press the pump lever down as far as it will go. – Screw on threaded ring down to thread end. Tighten screw connections of the compressing device. Close pressure relief screw 5. Compress the disk stack to facilitate loosening of the bowl lock ring. Compression: See data sheet. Loosen the bowl lock ring by ham- mering against the handle of the wrench with a mallet (left-hand thread). Fig. 35 If the lock ring is jammed tight, loosening can be considerably facilitated by heating the upper part of the bowl bottom with steam or hot water. Do not use any other sources of heat, e.g. blow torch or welding torch. 2325-9001-020 / 0806 46 Westfalia Separator AG Dismantling the compressing de- vice: Move pump lever of compressing device down as far as it will go to prevent it from jumping back. Loosen pressure relief screw 5. Unscrew threaded ring 2 (left-hand thread). Remove hydraulic unit 3 and disk 4. Unscrew bolt 1 (left-hand thread). Fig. 36 Unscrew bowl lock ring completely and lift it out using device 1 and eye bolt 2. Fig. 37 Insert disk 1 in the distributor neck. Screw lifting device 2 onto the bowl top. Force off the bowl top by turning the spindle clockwise and lift it out. Take disk 1 out of the distributor neck. Fig. 38 Screw lifting device 1 into the dis- tributor. Force off the distributor together with the disc stack by turning jack- screw clockwise. Lift out distributor with disk stack. Fig. 39 2325-9001-020 / 0806 Westfalia Separator AG 47 Place pressure piece A of the lifting device (sliding piston) on the hub of the bowl bottom. Grease outer surface of the pres- sure piece. Fig. 40 Screw lifting device 1 onto the slid- ing piston (left-hand thread).. Force sliding piston off the bowl bottom by turning threaded spindle 2 clockwise. Lift off sliding piston. Make sure that the sealing lip of the sliding piston does not get dam- aged. Fig. 41 Pressing off the bowl bottom: Screw pressure piece 7 into threaded bolt 4. Screw eye bolt 3 into the upper bolt end 4. Screw the entire device into the thread of the bowl bottom as far as it will go (left-hand thread). Force the bowl bottom off the spin- dle cone using the wrench which is placed over the hexagon at the up- per threaded bolt end. Fig. 42 2325-9001-020 / 0806 48 Westfalia Separator AG 4.4 Assembling the bowl Handle bowl parts with care. Assemble the bowl on a rubber mat or wooden pallet. Grease threads and guide surfaces of the bowl parts. Replace worn gaskets. For tools, see order-specific parts list. Transport the bowl bottom using the threaded spindle. Fig. 43 Thoroughly clean gasket groove in the sliding piston and apply a thin film of grease. Insert gasket into the groove of the sliding piston. Fig. 44 Insert the gaskets in the grooves in the bowl bottom. Fig. 45 2325-9001-020 / 0806 Westfalia Separator AG 49 Place pressure piece 1 of lifting device for sliding piston onto hub of bowl bottom. Fig. 46 Grease guide surfaces of the sliding piston and bowl bottom. Insert the sliding piston using the lifting device so that the "O" marks are perfectly aligned. Lower the sliding piston slowly by turning the jackscrew counter- clockwise until the arresting pins of the bowl bottom catch into the holes of the sliding piston. If necessary, jolt the piston until it snaps into posi- tion. Fig. 47 Make sure that the sealing lip B of the sliding piston does not get dam- aged. Attention! After inserting the sliding piston take out pressure piece A. Turn distributor through 180o. Install lower distributor 1 so that the cams in the lower distributor and distributor – are aligned, Secure lower distributor 1 against falling out by screwing in cylindrical pin 2. Turn around distributor again. Fig. 48 2325-9001-020 / 0806 50 Westfalia Separator AG Stack the disks onto the neck of the distributor in numerical order, be- ginning with number 1. Fig. 49 Grease contact surfaces. Install distributor together with disks in the bowl bottom. The "O" marks on the bowl bottom and distributor must be aligned; the grooves in the bowl bottom will then catch into the locking devices of the distributor. Fig. 50 Install separating disk with inserted gaskets. The "O" marks on the separating disk and bowl bottom must be aligned. Fig. 51 Clean and grease guide surfaces and threads of the bowl bottom. Insert disc 1 of the lifting device (bowl top) into the distributor neck as a support for the lifting device. Fig. 52 2325-9001-020 / 0806 Westfalia Separator AG 51 Insert the gaskets in the grooves of the bowl top. If the main bowl gasket has to be replaced, see chapter “Replacing main gasket”. Clean and grease guide surfaces of the bowl top. Fig. 53 Place bowl top on bowl bottom with the aid of the lifting device A. Slowly lower the bowl top by turning the threaded spindle B counterclock- wise. Make sure that the arresting piece of the bowl bottom catches into the groove of the bowl top. The "O" marks on both parts must be aligned. Unscrew disk from the distributor neck. Fig. 54 Check and grease threads as well as contact and guide surfaces (see arrows). Fig. 55 Place bowl lock ring on the bowl bottom using lifting device 1 and eye bolt 2. First screw in the bowl lock ring using the pin spanner by hand (left- hand thread). Fig. 56 2325-9001-020 / 0806 52 Westfalia Separator AG Take disk 1 of the lifting device out of the distributor neck. Fig. 57 Mounting the compressing device: Place disc 4 on the bowl top. Screw bolt 1 as far as it will go into the bowl bottom (left-hand thread). Insert hydraulic part 3 into the cen- tering recess of the disc. Screw on threaded ring 2 until its upper edge is flush with end thread of bolt 1 (left-hand thread). Fig. 58 To prevent damage to threads: Screw in threaded bolt completely. Screw on threaded ring down to thread end. Attention! If the threaded ring cannot be screwed down completely, then the piston and the cylinder of the compressing device are too far apart. In this case: Bring piston and cylinder into initial position: – Loosen pressure relief screw 5 by two turns. – Press the pump lever down as far as it will go. – Screw on threaded ring down to thread end. Tighten screw connections of the compressing device. Close pressure relief screw 5. Compressing the disk stack: Pressure must be gradually applied to the disk stack until the max. disk com- pression is attained, see data sheet. Each pressure increase should be approx. 50 bar. After each pressure increase, tighten bowl lock ring further. When the max. disk compression of (see data sheet) has been reached, the "O" mark on the bowl lock ring must be approx. 1 -2 cm apart from the "O" mark on the bowl bottom. Fig. 59 2325-9001-020 / 0806 Westfalia Separator AG 53 If the maximum pressure is not attained and grease flows out of the stroke limit- ing hole, bolt 1 has not been screwed far enough into the bowl bottom. The compressing device is not ready for use again until bolt 1 and threaded ring 2 have been brought back into the position as described above. When compressing the disc stack, make sure that the arresting piece of the bowl bottom snaps into the groove of the bowl top and that the bowl top does not become twisted when lowered. Hit wrench handle with the mallet to obtain "O" mark alignment (left- hand thread). Fig. 60 If the lock ring can be tightened by hand up to the “O” mark at maximum disk compression, add a spare disk or compensating disk. In the case of newly fitted disk stacks, the pressure in the disk stack can slacken due to settling of the disks. For this reason, check the pressure in the disk stack several times using the procedure described above. At least once a month in the first 3 months. Dismantling the compressing de- vice: Move pump lever of compressing device down as far as it will go to prevent it from jumping back. Only then undo pressure relief screw 5. Unscrew threaded ring 2 (left-hand thread). Remove hydraulic unit 3 and disk 4. Fig. 61 Unscrew the hex head screws of the pin spanner and remove it. Unscrew the eye bolt. Screw hex head screws with fitted gasket into the lock ring. Fig. 62 2325-9001-020 / 0806 54 Westfalia Separator AG Before placing the bowl on the spin- dle, oil the upper part of the spindle (thread and cone). Clean and dry the conical part of the spindle and the inside of the bowl hub with a cloth to ensure proper fitting. Fig. 63 Screw the eye bolt onto the threaded rod. Fig. 64 Lower the bowl on the spindle. Dismantle the device. Fig. 65 Screw spindle screw (with inserted gasket) firmly into the spindle (left- hand thread). Fig. 66 2325-9001-020 / 0806 Westfalia Separator AG 55 4.4.1 Fitting the centripetal pump Introduce feed tube 1 with gasket 2 into the bowl. Fit lower distributor 3 with inserted gasket 4. Pay attention to correct positioning! Put spacer 5 and gasket 6 on the feed tube. Place on centripetal pump chamber cover 7 with inserted gasket 8. Pay attention to correct positioning! Install lower centripetal pump 9 with gasket 10. Mount centripetal pump chamber cover 11 with gasket 12. Mount distance sleeve 13 with gas- ket 14. Install upper centripetal pump 15 with gasket 16. Fig. 67 Pay attention to correct position- ing; check assembly of centripe- tal pump components. Fig. 68 Clean and grease threads on bowl top and in the lock ring. Install upper centripetal pump 1 with fitted gaskets and tilt towards the bowl centre. Fig. 69 2325-9001-020 / 0806 56 Westfalia Separator AG Mount centripetal pump chamber cover pos. 1. Fig. 70 Place on centripetal pump chamber cover with inserted gasket. Pay attention to correct positioning! The "O" marks must be aligned. Fig. 71 Clean and grease threads on bowl top and in the lock ring. Screw on the lock ring by hand and tighten it by hammering against the handle of the annular wrench (left- hand thread). Fig. 72 2325-9001-020 / 0806 Westfalia Separator AG 57 4.4.2 Installing the swivel-type actuator Fig. 73 Exploded view of the swivel-type actuator The swivel-type actuator need not be dismantled when the bowl is to be re- moved. If, however, the swivel-type actuator has to be dismantled in order to re- place a defective component, the bowl has to be removed and reinstalled as shown in Fig. Fig. 73. Also keep in mind the following points: The pointer indicating the angle of setting must be on "0". Place on the drive pinion as shown in Fig. Fig. 73. 2325-9001-020 / 0806 58 Westfalia Separator AG 4.5 Assembling the feed and discharge connections Screw two ring nuts opposite each other onto the studs of the hood. Fig. 74 Shorten the chains of the lifting de- vice. The chain link must be put cross- wise on hook A (see adjacent small figure)! Hang the shortened lifting device into the lifting-eye nuts and place the hood on the solids catcher. Bolt hood and solids catcher to- gether using hex head screws. Fig. 75 Thread two eye bolts 1 into ring 2. Insert gasket 3. Place on ring 2 together with the swivel-type actuator. Fasten ring 2 by means of hex head screws 5 with installed lock washers 4. Fig. 76 The pointer must be on "0" (see arrow). Place toothed segment 3 on cen- tripetal pump 2 (watch for "O" mark alignment). Insert toothed segment 3 so that the marks of the teeth of segment 3 and of the drive pinion are placed oppo- site to each other (see arrows). For this purpose, the centripetal pump has to be turned while the toothed segment is held in a slightly Fig. 77 inclined position. 2325-9001-020 / 0806 Westfalia Separator AG 59 Place on protecting-case halves 1 and 2, and fasten them with hex head screws 3. Fig. 78 Install the discharge. Connect the feed and discharge lines. Connect vent line 2. Screw tight connection piece 1 with inserted gasket. Fig. 79 Connect the following lines: – Cooling lines of the hood cooling, – flush water line, – supply line to hood flushing. Make electrical connections to the contact pressure gauge. Fit sight glass illumination. Connect current supply 1 and com- pressed-air supply 2. Note: The protecting cases must be in place - danger of crushing! Caution Fig. 80 2325-9001-020 / 0806 60 Westfalia Separator AG 4.6 Replacing the main bowl gasket (bowl top) Removal Screw wooden screw 1 into the gasket. Lever out the gasket with screw- driver 2. Fig. 81 Fitting Insert the gasket in the cleaned groove of the bowl top (with the nar- row side towards the bowl top). Drive the gasket evenly into the groove. If the diameter of the gasket is too small, place it in a water bath of 70 - 80 oC for about 5 minutes. The gas- ket will then assume its original di- mensions. Fig. 82 Drive the gasket into the groove so far that the sealing area of the gas- ket does not protrude above surface "A" of the bowl top by more than 1 mm. Fig. 83 2325-9001-020 / 0806 Westfalia Separator AG 61 4.7 Bowl valves Remove and clean the bowl valves once a month. Screw wrench 1 (bowl valve) into the bowl valve. Fig. 84 Push sleeve a of the wrench to- gether with the pins into the holes of the bowl valve. Tighten collar nut b. Unscrew bowl valve from bowl bot- tom using socket wrench 1. Fig. 85 If the valve piston 2 remains stuck in the bowl bottom while pulling out the valve: Screw wrench 3 (for valve piston) into the valve piston. Pull the valve piston out of the bowl bottom by means of the wrench. Fig. 86 At the same time, check the gaskets and replace them if necessary. 2325-9001-020 / 0806 62 Westfalia Separator AG Use the tools stated in the parts list to fit the gaskets. Stretch the gasket 3 over the ex- panding mandrel 4 and fit in piston valve 1. Fig. 87 Stretch gaskets 3 and 5 over ex- panding mandrel 2 and 4 and fit in piston 1. Fig. 88 For installation proceed in opposite order of removal. Pay special attention to the following: Moisten gaskets. Grease threads. Screw in valve as far as it will go, but not too tightly . The front face of the valve housing must be flush with the outer wall of the bowl bottom. 2325-9001-020 / 0806 Westfalia Separator AG 63 4.8 Disk stack compressing device 1 Filling device 2 Clamping piece 3 Grease cartridge 4 Pumpenkopf 5 Non-return valve 6 Pressure chamber 7 Hydraulic cylinder 8 Piston 9 Bolt 10 Disc 11 Hydraulic part 12 Threaded ring 13 Stroke-limiting hole 14 Venting screw 15 Pressure gauge (0-600 bar) 16 Pressure relief screw Fig. 89 Operating principles The pump presses grease at a high pressure into pressure chamber 6. The increase in pressure in the pressure chamber displaces piston 8 in relation to hydraulic cylinder 7. The hydraulic part 11 (piston, hydraulic cylinder) is bolted securely to the bowl bottom by means of bolt 9 and threaded ring 12. When the pressure increases in pressure chamber 6, piston 8 is forced down- wards. The force produced is transferred via disk 10 on to the bowl top. The disc stack is compressed. Required compression: see datasheet maximum pressure: see datasheet Pump The pump produces a pressure of max. 400 bar. It consists of: pump head grease cartridge filling device non-return valve 2325-9001-020 / 0806 64 Westfalia Separator AG Filling the grease cartridge Cartridge filling: 450 g special grease K2R The grease cartridge of the compressing device is filled with special grease be- fore shipment. Actuate clamp piece 2 and pull the filling device 1 upwards. Unscrew grease cartridge 3 from pump head 4. Fill in grease, approx. 450 g. Screw grease cartridge 3 into pump head 4. Actuate clamp piece 2 and push filling device 1 into grease cartridge 3. Fill the grease cartridge only with WS special grease K2R. If there is no build-up of pressure, the following must be checked: Is the pressure relief screw 16 screwed in tightly? Is there enough K2R grease in the grease cartridge? Has piston 8 travelled too far out of hydraulic cylinder 7? If yes: Unscrew pressure relief screw 16 a little way. Press piston 8 back into hydraulic cylinder 7. This must be done in the absence of pump pressure. Re-tighten pressure relief screw 16. 7 Hydraulic cylinder 8 Annular piston 9 Bolt 16 Pressure relief screw Fig. 90 If grease oozes out through the stroke limiting hole 13, bolt 9 and threaded ring 12 have not been screwed into their final position, and the stroke is too long. 2325-9001-020 / 0806 Westfalia Separator AG 65 5 Technical information 5.1 Constructional features.......................................................................... 66 5.2 Operating principles of the bowl ............................................................ 68 5.3 Operating principles of the hydraulic system of the bowl ...................... 70 5.3.1 Bowl ejection..........................................................................................71 5.4 Operating water connection...................................................................72 5.4.1 Solenoid valves......................................................................................73 5.5 Swivel-type actuator for control of the centripetal pump ....................... 73 2325-9001-020 / 0806 66 Westfalia Separator AG 5.1 Constructional features Fig. 91 Self-cleaning bowl: – The bowl can be emptied during operation by means of a hydraulically ac- tuated sliding piston 17. Closed feed and discharge of the product phases: – The product is fed into the machine through a closed line system. – For product observation illuminated sight glasses are fitted in feed 3, clean oil discharge 4 and heavy phase discharge 2. – A pressure switch monitors the discharge pressure of the light phase. – Soap or gums are discharged through a closed discharge pipe. "Fine Tuner": – With the aid of "Fine Tuner" 6 the separating zone in the disk stack can be altered while the separator is running. By this means, the separator can be optimally adapted to changes in the product (e.g. different oil types). During start-up and bowl ejections the separating zone can temporarily be displaced to the centre to prevent oil carry-over at the separating disk outer diameter. Hydrohermetic feed: – The product is fed into the bowl gently and with slight overpressure through hydrohermetic feed 10. "Steam seal": – A hydrohermetic seal 9 prevents clouding of the oil due to vapours from the inlet chamber. 2325-9001-020 / 0806 Westfalia Separator AG 67 "Bowl Flush": – Liquid can be fed into the outer solids space via a separate channel 5. By this means, surplus lye or acid can be flushed out or a high-viscous phase can be diluted and conveyed more easily out of the bowl. – The separator is also equipped with a direct drive (without belt and gear) three-phase AC motor for FC operation external lubricating oil unit for oil circulation lubrication 2325-9001-020 / 0806 68 Westfalia Separator AG 5.2 Operating principles of the bowl Fig. 92 1 Control unit 14 Flush water channel (”Bowl Flush”) 2 Heavy phase discharge 15 Solids holding space 3 Feed 16 Solids ejection ports 4 Discharge (light phase) 17 Sliding piston 5 Flush water channel (”Bowl Flush”) 18 Closing chamber 6 Centripetal pump – heavy compo- 19 Piston valve nent (”Fine Tuner”) 7 Centripetal pump – light component 20 Opening water 8 Distributor 21 Closing–water 9 ”Steam seal” 22 Metering piston 10 Hydrohermetic feed 23 Control air 11 Disk stack 24 Filling water / opening–water 12 Rising channels 25 Cooling medium 13 Separating disk channels The bowl is used to separate mixtures that consist of – a liquid (oil) and – pasty substances (soapstock or gums) with simultaneous removal of the solids contained in the mixture. The product flows through feed 3 into the bowl, and is separated in disk stack 11. The disk stack consists of a large number of conical disks placed on top of one another. Due to the narrow interspaces between these disks the liquid is split up into thin layers and the settling path is minimized. 2325-9001-020 / 0806 Westfalia Separator AG 69 The light component flows to the bowl center, then flows to the centripetal pump chamber, is discharged under pressure by centripetal pump 7, and led off through discharge pipe 4. The heavy component flows out of the disk stack to the periphery, flows over the separating disk to the centripetal pump chamber, is discharged under pressure by centripetal pump 6, and is led off under gravity through a discharge pipe. The solids particles are flung against the underside of the disk above, slide outwards into the solids holding space 15, are periodically discharged through solids ejection ports 16. Solids ejection is initiated by control unit 1. 2325-9001-020 / 0806 70 Westfalia Separator AG 5.3 Operating principles of the hydraulic system of the bowl Closing the bowl When the bowl has reached its rated speed, solenoid valve 12 for closing water is opened briefly several times. The closing water flows into the clos- ing chamber 3 beneath the sliding piston 4. Due to the rotation, pressure builds up in the closing chamber. This pressure creates force in axial direction which presses the sliding piston against gas- ket 9 of bowl top, thus closing the sol- ids holding space 11 during the sepa- ration process. Closing chamber 3 is sealed by valve piston 7 which is pressed through centrifugal force against gasket 8 and thus closes discharge hole 10. In order to compensate for closing water losses, closing water and filling water are supplied every 5 mins for 1sec via an interval switching ar- rangement. Fig. 93 Opening the bowl (ejection) To empty the solids holding space opening water 13 is added which flows from injec- tion chamber 2 through feed hole 5 to piston valve 6. Due to hydraulic opening of the valve the water discharges from the closing chamber through hole 10: for partial ejection the closing chamber empties partially, for total ejection it empties completely. As the liquid level recedes the closing pressure acting on the underside of the sliding piston decreases quickly. As soon as it is smaller than the opening pressure acting on the upper side of the piston, the sliding piston is pressed downwards, thus opening the ejection ports in the bowl bottom: the solids are then ejected instan- taneously through the ejection ports 14 of the bowl. Once the ejection has taken place, – opening-water valve 13 closes – closing-water valve 12 opens. Piston valve 6 re-seals discharge hole 10 and the closing chamber fills with water again. The sliding piston is forced back into closed position. Fig. 94 2325-9001-020 / 0806 Westfalia Separator AG 71 5.3.1 Bowl ejection When to empty the bowl? The intervals at which solids ejections have to take place depend on the solids content and on the nature of the process liquid. If possible, the solids holding space should not be filled to the brim. As soon as the separation or separation efficiency starts to deteriorate, either a total ejection or partial ejection must be carried out. During a total ejection the whole bowl contents are ejected, during a partial ejec- tion only part of the bowl contents. Whether partial or total ejections or a combination of both are carried out de- pends on the mechanical behaviour of the solids during bowl ejection. Partial ejection Partial ejection is a term used to denote partial emptying of the solids holding space of the bowl. The product feed is not interrupted during partial ejections. The amount to be ejected can be adjusted externally during operation between 5 - 30 l. For partial ejection, opening water is fed to the hydraulic system via the meter- ing device E. The amount of solids to be ejected is primarily determined by the opening water volume. The opening water volume is adjusted on the metering device. Adjusting the amount to be ejected Adjusting by means of the adjusting screw of the metering device. Reduce ejection volume. Turn adjusting screw clockwise Increase ejection volume: Turn adjusting screw anti-clockwise Fig. 95 2325-9001-020 / 0806 72 Westfalia Separator AG 5.4 Operating water connection The operating water connection is equipped with solenoid valves, pressure re- ducer and pressure switch. The function of the pressure switch is to monitor the operating water pressure. If the pressure drops below a preset minimum value, an alarm is given and the separation program interrupted. Operating water connection: 1¼ in Operating-water pressure: Pmin. = 2,0 bar (with open closing water valve) Pmax. = 2,5 bar Operating water capacity: = min. 4000 l/h Air pressure for metering unit: Pmin. = 4,0 bar Pmax. = 6,0 bar Note: Prior to a partial ejection there is a brief water pressure increase in the operating water connection. This can be read off on pressure gauge 2. Adjust the air pressure for the meter- ing unit so that the heightened water pressure is lower than the maximum pressure marked on solenoid valve 1. Fig. 96 If the setting is wrong no partial ejection is possible. Standard operating water values: D Suspended matter in operating water: max 10 mg/l D Particle size: max. 50 µm D Hard- 12 odH separating temperature up to 55oC ness: 6 odH at separating temperatures above 55 oC To convert the hardness values stated use the follow- ing equation: 1odH = 1.79ofH = 1.25oeH = 17.9 ppm CaCO3 D Chloride content: 100 mg/l D pH value: 6.5 – 7.5 2325-9001-020 / 0806 Westfalia Separator AG 73 5.4.1 Solenoid valves The solenoid valves incorporated in the operating-water system are 2/2-way straight-way diaphragm valves with internal piloting. The solenoid coil is entirely embedded in epoxy resin which ensures protection against moisture, good dissipation of heat, and perfect electrical insulation. The valves are fully tropicalized. Maintanance The solenoid valves do not require special maintenance. Electrical faults Shut off main valve for operating-water. Fault Cause Remedies Valve does not func- Control unit defective. Contact servicing tion. staff. Connecting terminal Tighten screw of con- on terminal strip is necting terminal. loose. Coupler socket loose Tighten coupler or leaks. socket and replace gasket, if necessary. Solenoid coil defec- Replace complete tive. solenoid head. 5.5 Swivel-type actuator for control of the centripetal pump The swivel-type actuator is controlled by means of an electric unit signal. As au- xiliary anergy, instrument air (dry and free of dust) is required. Air pressure: Pmin = 4bar Pmax = 6 bar Flow rate: approx. 93 Nl/min ! The centripetal–pump diameters required a) for operation (" large diameter) and b) for start–up / partial ejection (" small diameter) are entered on the control unit. The values entered are transformed to a certain electric signal. This signal causes the centripetal pump to enter into the desired position. The actual position can be read from the separator. 2325-9001-020 / 0806 74 Westfalia Separator AG Note Notes Notizen Anotaciones Notizen Notes Note 2325-9001-020 / 0806 Westfalia Separator AG 75 6 Operation 6.1 Before start-up ....................................................................................... 76 6.2 Start-up ..................................................................................................77 6.3 Closing of bowl: .....................................................................................77 6.4 Water run after start-up..........................................................................78 6.4.1 Program control .....................................................................................78 6.4.2 Function diagram of partial ejection.......................................................81 6.4.3 Total ejection .........................................................................................82 6.4.4 Bowl ejection (manual) ..........................................................................82 6.5 Adjusting the separation efficiency ........................................................83 6.5.1 Adjusting the "Fine Tuner" .....................................................................83 6.5.2 Calculation of the "Fine Tuner" diameter...............................................84 6.5.3 Presetting separation.............................................................................84 6.5.4 Adjusting the hydrohermetic feed ..........................................................85 6.5.5 Final adjustment of separating efficiency ..............................................86 6.6 Product mode ........................................................................................86 6.7 Shut-down (Normal Off).........................................................................88 6.8 Shut-down (Emergency-Off) ..................................................................88 6.9 Run-down (overspeed) ..........................................................................89 6.10 After shut-down......................................................................................89 6.11 Prior to a long-term shut-down .............................................................. 89 6.12 Trouble shooting ....................................................................................90 2325-9001-020 / 0806 76 Westfalia Separator AG 6.1 Before start-up Note: – Instructions in the brochures: “Separators in explosion-hazarded zones”, “Machine controls for separators”, “Safety precautions on the separator”. – Process dependent modifications reserved – refer to the project-related documentation. – Only feed product which conforms to the specifications on the nameplate. Check that – the machine has been correctly assembled, – the bowl is fitted, – the bowl lock rings have been tightened securely, – the screws for fastening the hood and the feed and discharge housing are tightened securely, – the centripetal pump with connection piece is tight, – the frame drains are open, – enough oil has been filled in (see manual of external lubricating oil unit), Open shut-off valves in supply lines for – operating water, – cooling water – hood flush water, – control air Press "Release" button. Check that – the specified pressures are indicated on the respective pressure gauges for – operating water, – braking water – control air Fill the siphon (when cooling medium does not discharge via siphon). 2325-9001-020 / 0806 Westfalia Separator AG 77 6.2 Start-up Press the "Separator ON" button. – Signal lamp "Start" lights up. LED "Bowl standstill" on the mimic display of control unit goes out as soon as the drive rotates. Together with the main motor the external fan is switched on automatically. The bowl speed can be read off from the speed indicator. The power consumption of the main drive motor is indicated by the ammeter. After approx. 4 minutes start-up and reaching half the bowl speed, switch- over to run-up takes place speed-dependently. – Signal lamp "Run-up" lights up. After a further 8 minutes, switch-over to operation takes place speed- dependently. – Signal lamp "Operation" lights up. The operating speed is reached (see separator nameplate). The ammeter indicates the no-load current of the machine. The lubricating oil unit is started at a certain bowl speed (see data sheet). – The oil circulation is monitored by a pressure switch. If the pressure in the oil line drops below the minimum value, the fault is signalled. The separator is switched off after a pre-set delay time. If severe vibrations occur during start-up, stop the separator immediately via "Emergency-Off" and check when the bowl is at rest whether the bowl is cor- rectly assembled and thoroughly cleaned. Separators equipped with a vibration monitoring system are continuously monitored for unduly high mechanical vibrations and automatically stopped upon exceeding the limit value stage 2. Never initiate a total ejection when the separator is vibrating severely. Strong unbalance of the separator may result. Damage of dame to assets and persons due to machines flying round. Attention! 6.3 Closing of bowl: After having switched over from acceleration to operation, two total ejections are carried out automatically in order to close the bowl. Unless this program has been activated, the two total ejections have to be initiated manually by pressing the corresponding function key. To prevent water losses, closing water is injected every 5 minutes for one sec- ond. All program time settings are variable. Closing-water injection is indicated by an LED in the separator symbol on the timing unit. 2325-9001-020 / 0806 78 Westfalia Separator AG 6.4 Water run after start-up Check that – metering device on the operating water connection is correctly adjusted. – program times are set on the control unit to suit the operating conditions. Feed separator with water. Check that the bowl is watertight. – Bowl leakage is indicated by a higher reading on the ammeter. – When bowl leakage is detected, terminate the water run, press "total ejection" button. – Refill the bowl with water and check that it does not leak. – If the bowl cannot be made watertight after several attempts. Press "total ejection" button. Warm up the bowl for max. 15 minutes without water. The polyamide ring adapts to the sealing surface of the sliding piston. – Refill the bowl with water and check that it does not leak. – If bowl leakage persists, shut down the separator via "Normal Off". Dismantle and check the bowl after standstill (polyamide gasket, gaskets of bowl hydraulic system etc.). Ejection progress is shown by LEDs in the valve symbols. 6.4.1 Program control A PLC unit is used for automatic program control of the separator. Consult the control unit manual for further information. 2325-9001-020 / 0806 Westfalia Separator AG 79 Function of the metering device The metering device E is filled with water via filling valve A after every ejection. For partial ejection chamber F is sup- plied with compressed air. Through actuating the opening water valve D the adjusted water volume is displaced by air pressure and fed to the hydraulic system of the bowl. A Solenoid valve filling water B Solenoid valve closing water C Solenoid valve hood flush water D Solenoid valve opening water E Metering device F Air chamber P Solenoid valve cooling water Fig. 97 Program sequence Refer also to section 6.4.2. After the program time "Separation - Partial Ejection" has elapsed, a partial ejection is initiated automatically which is then repeated at identical intervals. Before each partial ejection the solenoid valve C "Hood flush water" opens for approx. 10 seconds. This time can be preset as the program time "Pre-flushing". Water is sprayed into the hood to prevent the solids to be ejected from sticking to the walls. For solids ejection the solenoid valves B "Closing water" and D "Opening water" open for 1 second. This time can be preset as the program time "Partial ejec- tion". The solenoid valve B "Closing water" remains open for a further 5 seconds after the ejection. The time is set via "Closing". At the same time the hood flush water valve stays open for the time "Post-flushing". The "Separation" program can be interrupted by pressing the "Partial ejection" button. A partial ejection is then triggered. After termination of this forced partial ejection the control program automatically switches back to "Separation". Before each partial ejection the "Fine Tuner" is contracted to a small centripetal pump diameter (see 6.4.2-"Ta"). After each ejection the centripetal pump is extended to the large centripetal pump diameter after time (see 6.4.2 - "Tb"). These times are adjustable. 2325-9001-020 / 0806 80 Westfalia Separator AG Setting the program times: Program times... sec are process-related and must be set before start-up. Program time Pre–flushing approx. 10 secs Pre–flushing hood/solids collector. Partial ejection 1 sec This determines the opening time of the opening–water valve. This time must be longer than the displacement time of the opening water from the metering unit. The ejected solids volume depends on the preset volume in the metering unit. Secondary flushing approx. 20 secs Flushing the hood and solids collector after an ejection. Closing 5 sec Closing water addition after an ejection. Metering device 3 secs Continued control of air for metering device after partial ejection. Filling water 2 secs Delayed filling water supply after partial ejection. Total ejection 10 secs (not variable) Addition of opening water during total ejection. Waiting approx. 60 secs Waiting time after total ejection for speed recovery of bowl. Delay ejection after con- Capacity–dependent 1) tracting centripetal pump Displacement of the separating zone to (Ta) the centre to enable more heavy phase to enter the bowl. Delay centripetal pump Capacity–dependent 1) travel–out after ejection Filling the bowl with heavy phase. (Tb) Centripetal pump travel–out Capacity–dependent 1) delay (Tc) When product is first fed into the bowl, the bowl must be filled with heavy phase to the extent that there is no carry–over when the centripetal pump is extended. 1) The higher the capacity, the shorter the time. 2325-9001-020 / 0806 Westfalia Separator AG 81 6.4.2 Function diagram of partial ejection Program times Fig. 98 Setting the program times: See control unit manual 1) When the waiting period for resuming the bowl speed has elapsed, no automatic switch–over to ”separation” will take place. 2) These functions are provided in the control unit and can be adjusted if an automatic water valve has been installed. Ta Delay of ejection after contracting the centripetal pump) Tb Delay in extending the centripetal pump after ejection Tc Delay in extension of centripetal pump (after starting with product). 2325-9001-020 / 0806 82 Westfalia Separator AG 6.4.3 Total ejection During cleaning-in-place total ejections can only be initiated manually with the control unit. (Automatic cleaning-in-place requires a separate CIP unit, see rele- vant brochure.) During a total ejection the whole bowl contents are ejected. Never initiate a total bowl ejection when the machine is vibrating severely (bowl unbalance). Attention! To trigger a total ejection, press function key "Total ejection". If the installation is correctly set up (see connection diagram of control unit), the feed pump is automatically switched off by pressing push button "total ejection" and automatically re-started approx. 1 min. after completion of the total ejection. The interruption of the feed to the bowl by switching off the feed pump is neces- sary for the bowl speed to recover, which drops slightly during total ejections. Once the bowl has been filled again (observe increasing discharge pressure of centrifuge), a further total ejection can be carried out by again pressing push button "total ejection". Should the feed pump fail to stop automatically during a total ejection, it must be switched off manually and re-started 1 min. after total ejection. 6.4.4 Bowl ejection (manual) In the case of control unit failure or defective solenoid valves the separa- tor can be controlled manually: Partial ejection Open closing water valve B and filling valve A with the hand actuated lever. Open opening-water valve D briefly (approx. 1 sec). After the partial ejection leave closing- water valve B open. Total ejection Switch off the product pump. Open closing water valve B and filling valve A with the hand actuated lever. Open opening-water valve D with the hand actuated lever until the ejection noise has died down. Close opening water valve D and filling valve A; leave clos- ing water valve B open. Switch on the product pump again 1 minute after the total ejection. Fig. 99 2325-9001-020 / 0806 Westfalia Separator AG 83 6.5 Adjusting the separation efficiency To achieve perfect separation of the liquid mixture, the bowl must be adjusted to the different densities. To do this, – first adjust the "Fine Tuner" (6.5.1) – and then the hydrohermetic feed system (6.5.4). – Then carry out final adjustment of the "Fine Tuning" (6.5.5). 6.5.1 Adjusting the "Fine Tuner" The bowl is adjusted to the different densities of the mixture by altering the di- ameter of the "Fine Tuner". The required diameter of the "Fine Tuner" can be determined using the formula below. The general rule of thumb is: Small "Fine Tuner" diameter with a low density difference, Large "Fine Tuner" diameter with a large density difference. When separating pasty substances, the diameter of the "Fine Tuner" not only depends on the densities of the two components but also on the flow character- istics of the heavy component. In almost all cases a larger diameter of the "Fine Tuner" should be selected than is actually required by the difference in densities of the light liquid and the heavy pasty component. 2325-9001-020 / 0806 84 Westfalia Separator AG 6.5.2 Calculation of the "Fine Tuner" diameter The diameter of the "Fine Tuner" can be determined with the aid of the formula below. It should be noted that the densities are dependent on the temperature. To de- termine the "Fine Tuner" diameter, those densities must be entered that corre- spond to the separating temperature. gheavy phase = 1.0484 kg/dm3 Doil – centripetal = 120 mm (im- pump mersed) 3 goil = 0.88 kg/dm Dseparat- = 426 mm (centre ing zone rising channel) ! heavy phase (D separating zone ² - D heavy phase ²) " ! oil (D separating zone ² - D oil ²) Dheavy phase = D"Fine Tuner": ! oil D heavy phase " D separating zone ² # $ ( D separating zone ² # D oil#centripe ² ) ! heavy zone Whether the correct diameter for the "Fine Tuner" has been selected can be es- tablished by checking the position of the separation zone which forms between the light and heavy phase in the bowl. The middle of the separating zone is the separating line; it is almost always visible on the underside of the disks after opening the bowl. It is sufficient to check a few of the uppermost disks. The separating line should be situated in the outer third of the rising channels. 6.5.3 Presetting separation Setting the separation on the machine is done by entering the desired centripe- tal pump diameter on the control unit. The selected centripetal pump diameter should initially be slightly smaller than needed. This procedure provides less risk of carry-over when the hydrohermetic feed is adjusted in the next step. Setting possibilities: Input of the large centripetal pump diameter: max 245 mm – The working diameter of the "Fine Tuner" is adjusted (calculated from 6.5.2), i.e. separation takes place in this position. Input of the small centripetal pump diameter: min. 172 mm – The position is defined to which the "Fine Tuner" travels during start-up and solids ejection. The standard value is a diameter of approx. 185 mm. 2325-9001-020 / 0806 Westfalia Separator AG 85 6.5.4 Adjusting the hydrohermetic feed Fig. 100 The values shown in the diagram are based on measuremens with turbine oil and water. They should be considered as reference only. When treating other products, the range of operation might be different. Determine feed capacity. Determine feed pressure from the above diagram. Adjust the determined feed pressure by throttling the light-phase (oil) dis- charge. Note: – If the feed pressure exceeds the permissible value Pmax, there will be an overflow into the heavy phase. – if the pressure falls below Pmin, the system is not sufficiently filled, the hy- drohermetic feed does not work. 2325-9001-020 / 0806 86 Westfalia Separator AG 6.5.5 Final adjustment of separating efficiency After having finally adjusted the hydrohermetic feed, carry out final adjustment of the "Fine Tuner". Set the optimum separating efficiency by entering the large centripetal pump diameter. - The light phase contains part ය Increase the diameter of the ”Fine of the heavy phase. Tuner”. - The heavy phase contains part ය Reduce the diameter of the ”Fine Tuner” of the light phase. or check the discharge pressure to make sure that no overflow from light to heavy phase has occurred. Note: The light phase centripetal pump is only needed for adjusting the hy- drohermetic feed. Attention! – The hydrohermetic feed is throughput-dependent, i.e. it has to be read- justed when the throughput changes. The "Fine Tuner" is intended for setting the separating zone. 6.6 Product mode Prior to feeding oil, supply cold or hot water to the bowl, depending on the process, until the separating temperature is reached (this is of particular importance when treating oils that tend to emulsify easily). Then stop the process water supply. The water forms a water seal in the bowl which prevents the oil from discharg- ing through the water outlet. Open the hand shut-off valve in the product feed line, if provided. Press „Product ON" key: – Switch on the separation program. – Oil metering pump on or product valve open. Adjust the throughput capacity. – The "Fine Tuner" is positioned for a small centripetal pump diameter. Carry- over is thus prevented. As soon as enough heavy phase has formed inside the bowl, the centripetal pump is positioned for a large diameter. The period to be provided for this step can be preset (see 6.4.2). Throttle the pressure in the oil discharge line so that the hydrohermetic feed works. Carry out final adjustment of the "Fine tuner" (6.5.5). After the pressure switch on the clean oil side has responded the LED „PAL" goes out. Monitoring of the clean oil discharge is disabled for the program time „delay discharge pressure". The program time starts with „Separation". If the pressure switch responds during separation, the product feed valve closes automatically or the oil metering pump is switched off and the separa- tion program is interrupted. The LED „PAL" flashes. Be sure to feed process water again before restarting with product. 2325-9001-020 / 0806 Westfalia Separator AG 87 The throughput capacity of the separator (i.e. supplied liquid volume per unit of time) depends on – the viscosity, – the temperature, – the difference in densities of the components to be separated, – the nature of the heavy component to be separated, – the desired degree of purity of the light component. In the case of longer interruptions in operation, e.g. due to no product supply, we recommend carrying out one or two partial ejections by pressing the „Par- tial ejection" key to avoid compacting of the heavy phase in the bowl. The bowl is not allowed to run without liquid supply for more than 15 minutes, as otherwise it would result in overheating of the bowl mate- Attention! rial. The separation program including the partial ejections is carried out automati- cally by the control unit. The running program can be interrupted by pressing the „Partial ejection" key which triggers a bowl ejection immediately. The function diagram shows the program sequence for partial and total ejec- tions. The program sequence is indicated in the mimic diagram of the control unit by means of LEDs. 2325-9001-020 / 0806 88 Westfalia Separator AG 6.7 Shut-down (Normal Off) Press function key "Separator 0". Product feed pump off. – Product feed valve closes. – Braked run-down of separator through frequency converter with feedback facility. – Signal "operation" goes out. – Total ejection takes place. – Valves in the separator discharges are opened (control air bled from con- stant pressure valves). – The lubricating oil unit switches off at a certain bowl speed (see data sheet). – Signal "bowl standstill". Do NOT loosen any part of the separator before the bowl is at a standstill! Danger of injury to persons through rotating bowl parts. CAUTION! 6.8 Shut-down (Emergency-Off) Shut-down (Emergency-Off) can be initiated: by vibration stage 2, by vibration stage 1 after 5 minutes, manually. Do not supply opening water! – Product feed valve closes. – Braked run-down of separator through frequency converter with feedback facility. – Run-down water valve open (max. 20 m3/h). – Switch-over in the separator discharge from product path to sewer. – Valve in separator discharge is open (control air bled from constant pres- sure valve). – Separation program off. – The lubricating oil unit switches off at a certain bowl speed (see data sheet). At bowl standstill – Run-down water valve closed. – Signal "bowl standstill". Do NOT loosen any part of the separator before the bowl is at a standstill! Danger of injury to persons through rotating bowl parts. CAUTION! When shut-down (Emergency-Off) is caused by vibration, Open and clean bowl before re-starting. 2325-9001-020 / 0806 Westfalia Separator AG 89 Check if bowl is correctly assembled and check drive. Observe safety precautions when carrying out maintenance work! 6.9 Run-down (overspeed) – Product feed valve closes. – Main motor off. – Switch-over in the separator discharges from product path to sewer. – Valves in the separator discharges are opened (control air bled from con- stant pressure valves). – Separation program off. – The lubricating oil unit switches off at a certain bowl speed (see data sheet). At bowl standstill – Signal "bowl standstill". Do NOT loosen any part of the separator before the bowl is at a standstill! Danger of injury to persons through rotating bowl parts. CAUTION! After shut-down through overspeed before renewed start-up – Open and clean the bowl. – check programmed output frequency on the frequency converter, – check transmission ratio of the drive, – Check speed limit value setting on the operator panel, – Check control electronics on the frequency converter. 6.10 After shut-down Close hand shut-off valves in the feed and discharge of the separator. Close manual shut-off valves in supply lines for – operating water, – control air, – cooling liquid, – hood flush water, When the machine is shut down for prolonged periods, follow the instruc- tions in the chapter “Cleaning”! 6.11 Prior to a long-term shut-down If the separator is not operated for a prolonged period, a number of basic points must be observed. Only in this way can it be ensured that no damage occurs to the separator when it is later put back into operation. The exact procedure for preparing a separator for a prolonged shut-down is described in the chapter cleaning. 2325-9001-020 / 0806 90 Westfalia Separator AG 6.12 Trouble shooting Short-term mains failure Product feed valve closes. Main motor OFF. Separation program OFF. Automatic valves close. When power returns Press "reset" function key. Press "Separator I" function key. After switching to "Operation" two total ejections are carried out automatically. Note: The machine is shut down (Emergency Off) before pressing the Reset" key. Long-term mains failure with bowl standstill Product feed valve closes. Main motor OFF. Separation program OFF. Automatic valves close. Do not loosen any part of the separator before the bowl is at a standstill! Caution Open and clean bowl before re-starting. Note safety precautions when carrying out maintenance work! 2325-9001-020 / 0806 Westfalia Separator AG 91 Faults Causes Automatic Remedies responses Motor temp. stage 1 Motor overloaded. Visual and audible alarm. Extend ejection intervals, C (160 o ) Motor defective. reduce throughput capacity. TAH Ejection intervals too short. Check that bowl is tight, water Ambient temperature too high. and mechanical brakes are No or insufficient motor cool- serviceable. Check motor ing. current: Observe ammeter. If motor current is too high, check drive. Let motor idle and check after approx. 15 minutes if the signal can be acknowledged by pressing the ”reset” button. If that is the case, the motor temperature has dropped. Then perform a total ejection and check if motor fan system is dirty. If necessary, shut down the Separator and clean external fan. Motor temp. stage 2 No remedial action was taken Visual and audible alarm. Check drive. C (180 o ) after fault indication Stage I”. Main motor OFF. Check motor. TAH Motor overloaded. Separation program OFF. Drive defective. Product valve closes or Motor defective. product pump off. Total ejection Overcurrent Bowl leaks. Visual and audible alarm. Check if IAH Bowl rotates in solids. Main motor OFF. – bowl is tight, Water brake is in operation Separation program OFF. – solids discharge is blocked, .Drive defective. Product valve closes or – bowl rotates in solids. Motor overloaded. product pump off. Clean solids collector and Single phase run Total ejection frame .Motor defective. Check that water brake is serviceable (solenoid valve for brake water leaks). Check motor. Check drive. Vibration stage 1 Unbalance of bowl due to Total ejection While the bowl is filled perform 22,5 % = 4,5 mm/s uneven solids ejection or due Visual and audible alarm. several partial ejections by t > 10 sec NAH to incorrect assembly of bowl. pressing the respective button. Drive defective (bearings or A 5 minute delay time starts vibration absorbers) simultaneously. If unbalance cannot be elimi- nated during this time, separa- tor is shut down via ”emer- gency off”. Vibration stage 2 Visual and audible alarm. Open and clean the bowl. 35 % = 7 mm/s Shut–down ”Emergency Off”. t >5 sec NAH If bowl is not dirty and is cor- rectly assembled, check drive (bearings and vibration ab- sorbers). 2325-9001-020 / 0806 92 Westfalia Separator AG Faults Causes Automatic Remedies responses Fan [IMG,0,20,3,2]FL Fan motor defective. Visual and audible alarm. Main Check fan motor. Fan motor overloaded. motor OFF. Clean fan. Single phase run. Separation program OFF. Fan motor off. Product valve closes or product pump off. Total ejection Lubrication FAL Lube oil flow interrupted. Visual and audible alarm. After Check lubrication system. Lube oil level too low. 5 minutes: Check monitoring system. Main motor OFF. Separation program OFF. Product valve closes or product pump off. Total ejection Operating–water Water pressure <Pmin or water Visual and audible alarm. Check water supply system. t >5 sec supply failure. Separation program OFF. Clean filter in pressure reducer. Product valve closes or product If the water pressure drops so pump off. far that the required water pressure does not build up within the max. possible sepa- rating time and no ejection is possible, the separator must be shut down and the bowl cleaned by hand. (If the per- missible retention time of the solids in the bowl is exceeded – product–dependent – the solids will harden and be ejected unevenly from the bowl. The result is severe unbalance during ejection). Speed min. RUN Bowl leaks. Visual and audible alarm. Carry out the following Slippage of flat Separation program OFF. checks at operating speed: belt. Starting time longer 12 Product valve closes or product minutes. pump off. – bowl for watertightness Water brake is in operation. – speed measuring device Drive defective. – limit value setting on speed indicator – solenoid valve for water brake at standstill: – drive – flat belt, replace when nec- essary 2325-9001-020 / 0806 Westfalia Separator AG 93 Faults Causes Automatic Remedies responses Ejection monitoring Water pressure too low. Visual and audible alarm. Initiate a solids ejection by (The signal is activated Water filter blocked. Separation program OFF. pressing the ”Total ejection” when there is no current Operating–water line Product valve closes or key and observe the ammeter. increase when an ejection leaks. Nozzles in the operat- product pump off. Check water pressure. is initiated. The speed ing–water feed are blocked. Clean filter in operating–water drops during ejections. Bowl hydraulic system is defec- line. Check operating–water Increased current con- tive. line for sumption brings the bowl Operating–water valves leakage. Clean nozzles and back up to operating defective. Opening time too bores in operating–water speed.) short. feed. Check operating–water Air supply to metering device valves. Check air supply to not operational: metering device. – pressure reducer – 3/2–way pilot valve If still no success, shut down separator! Check bowl hydraulic system and renew gaskets if neces- sary. 2325-9001-020 / 0806 94 Westfalia Separator AG Note Notes Notizen Anotaciones Notizen Notes Note 2325-9001-020 / 0806 Westfalia Separator AG 95 7 Cleaning 7.1 Cleaning-in-place...................................................................................96 7.2 Bowl .......................................................................................................99 7.3 Frame...................................................................................................100 7.4 Operating water feeding device...........................................................100 7.5 Cleaning the lube-oil vessel .....................................................................100 7.6 Prior to a long-term shut-down ............................................................101 7.7 Note on cleaning work on hoods .........................................................102 7.8 Note on cleaning work on disks...........................................................102 2325-9001-020 / 0806 96 Westfalia Separator AG 7.1 Cleaning-in-place After use, the separator must be cleaned in place. During CIP, cleaning solution is circulated through the separator and the con- nected system. Attention: Make sure that the cleaning solution emerging from the discharge lines of the separator cannot enter the product lines. Set changeover valves, if provided, accordingly. If no changeover valves are provided, the plant has to be modified accord- ingly. To prevent corrosion damage, only approved detergents should be used. Example: Henkel - 2 % lye (P3 Super LA) Bayer - 2 % caustic (Trosilin M alkaline) - Acid solution 0.5% (Trosilin M acid) 2325-9001-020 / 0806 Westfalia Separator AG 97 The following cleaning program is recommended: Program sequence Duration of the individual program steps 1. Pre–flushing Feed rate: approx. 5 m3/h 2 - 5 minutes Displacing the product with hot water 2. Caustic flushing temperature: 70 - 80 oC Feed rate: approx 5 m3/h 2 percent caustic solution (NaOH) (caustic soda free of chloride) Dislodging residual dirt 20 minutes Purging the piping with water Overflow 3. Intermediate flushing temperature: 70 - 80 oC Feed rate: approx. 5 m3/h hot water 2 -5 minutes total ejection 4. Neutralizing Temperature: 65oC Feed rate: approx. 5 m3/h Neutralizing with 0.5 % HNO3 solution 20 minutes Purging the piping with water Total ejection 5. Post-flushing Temperature: 70 - 80 oC Feed rate: approx. 5 m3/h Flushing out the HNO3 solution with water 5 minutes Total ejection approx. 30 seconds The total ejections must be initiated by pressing a button. The commands “Total ejection" can be automatically triggered from an external CIP control unit. 2325-9001-020 / 0806 98 Westfalia Separator AG Feed Light phase discharge Heavy phase discharge Pressure mea- surement Fig. 101 To obtain perfect cleaning of the bowl, the system has to be connected as fol- lows: The CIP solution is fed into the feed. The liquid emerging from the heavy-phase discharge is diverted into the oil discharge unthrottled. Thus, an internal circuit is formed whose throughput rate is greater than the feed rate. The volume that is fed flows off through the light-phase discharge. The oil discharge towards the tank is throttled (V3) as far as the motor current allows, or until overflow of the bowl occurs (Inom of drive motor - see name- plate). The volume of circulating liquid is set only by means of the oil valve V3. To prevent overload of the motor, the rated current (Inom) must not be ex- ceeded. Attention! 2325-9001-020 / 0806 Westfalia Separator AG 99 7.2 Bowl Cleaning of the bowls after separation is only required when the nature of the separated solids necessitates it. Experience will show how often the bowl has to be cleaned. The following points should be kept in mind: During the first few months of operation, the lock rings should be removed approximately every two weeks for greasing the threads to prevent seizing. Later on, the greasing intervals may be extended. However, the bowl should be dismantled at least every two months for thorough cleaning of the inner bowl parts. Never use metal scrapers or metal brushes for cleaning the discs and bowl parts. IMPORTANT All bowl parts have fine tolerances; it is therefore important that all parts are cleaned thoroughly and are free from burrs. Remove the gaskets from the bowl parts. Clean grooves and gaskets to prevent corrosion. Replace damaged or very swollen gaskets immediately. Swollen gaskets should be left to dry in a warm place so that they can regain their original dimensions and can be re-used. Carefully clean the small holes in bowl bottom and the two bowl valves for the supply and discharge of the operating-water to ensure trouble-free perform- ance of the solids ejections. Clean and wipe dry guide surfaces and threads of bowl parts and grease them. Spindle cone and inside of bowl hub should be oiled and then wiped clean and dry with a smooth rag. The solids catcher and solids collector bottom should also be cleaned every time. Re-assemble bowl immediately after cleaning. Otherwise the bowl parts must be protected against dust and dirt. 2325-9001-020 / 0806 100 Westfalia Separator AG 7.3 Frame When cleaning the frame: Never expose the machine to a direct water jet. It must be cleaned by hand, with a sponge or cloth. This applies especially to the motor, even if it is enclosed. 7.4 Operating water feeding device The strainer in the water pressure reducer and the small holes in the operat- ing water feeding device should be cleaned when necessary. 7.5 Cleaning the lube-oil vessel The lube oil vessel on the external lube oil unit has to be cleaned at regular in- tervals and after several oil changes, but after the number of operating hours stated in the “maintenance schedule” at the latest when the oil has to be changed because water or dirt has seeped into the drive, when the oil circulation decreases (pressure drop in the oil circulation line In this, case, the oil lines and channels in the drive have to be cleaned as well. Procedure: – Loosen the lube oil advance and return lines. For more instructions for cleaning the lube oil vessel, refer to the instruc- tion manual of the external lube oil unit. Instruction manual 2325-9001-020 / 0806 Westfalia Separator AG 101 7.6 Prior to a long-term shut-down Thoroughly clean the separator bowl and frame (see chapter “Cleaning”) Preserving the separator: Drain the lubricating oil. Fill the oil pan with a slushing oil, e.g. SHELL Ensis Fluid E or equivalent up to middle of sight glass. In the case of separators with an external lubricating oil unit, fill the lubricating oil vessel in accordance with the instructions in the “external lubricating unit manual”. Let the separator run with bowl until all the drive parts are coated with slush- ing oil. (Observe start-up instructions!) Remove the bowl from the spindle (see chapter “Bowl”). Oil the upper end of the spindle by hand. Permanent corrosion protection for separator drive parts with the specified slushing oil can be guaranteed for a maximum of 1 year. After this time, the bearings must be replaced as specified in the maintenance schedule. Wipe dry and grease all bowl parts and all unvarnished machine parts. The clean, grease-coated bowl should be kept in a dry place until it is used again. Remove all the gaskets and the drive belt and keep them in a cool, dry room, protected from dust and light, to prevent them from getting brittle. Check water shut-off devices for leakage. If necessary, disconnect water supply lines to avoid damage caused by drip water. Switch off the operating water supply (if fitted) at the mains to prevent inrush of water caused by inadvertent opening of the shut-off valve. Before re-starting: Drain the slushing oil. Fill the oil pan with lubricating oil (see chapter “Lubrication”). In the case of separators with an external lubricating oil unit, fill the lubricating oil vessel in accordance with the instructions in the “external lubricating unit manual”. 2325-9001-020 / 0806 102 Westfalia Separator AG 7.7 Note on cleaning work on hoods The following instructions must be followed during cleaning and maintenance work on hoods. Load suspension devices such as lifting devices for bowl or hood may only be used correctly and properly and for the intended purpose only. This means that work must be carried out as described in the separator manual. Caution Do not use damaged or incomplete load carrying equipment. Special safety precaution when turning over the hood: Unintended swinging or overturning of the hood must be prevented. Use the carrying straps as illus- trated. The minimum lifting capacity of the carrying strap must be double as high as the weight of the hood even under consideration of the applica- tion conditions. Fig. 102 7.8 Note on cleaning work on disks When mounting the disks, they are centrically guided over the distributor neck. If disks are dismantled in connection with servicing / manual cleaning and are stacked on one another outside the distributor, it must be ensured that the oni- cal disk surfaces do not slide into each other. To avoid damage, the disks should also be stacked centrically. 2325-9001-020 / 0806 Westfalia Separator AG 103 8 Drive 8.1 Drive.....................................................................................................104 8.1.1 Special risks of a separator .................................................................105 8.1.2 Safety precautions for maintenance and repair...................................108 8.2 Fitting and removing the motor............................................................112 8.2.1 Removing the motor ............................................................................112 8.2.2 Installing the motor ..............................................................................113 8.3 Removing spindle assembly, supporting disk......................................114 8.4 Dismantling the spindle assembly .......................................................116 8.5 Assembling the spindle unit .................................................................118 8.6 Replacing the rubber-metal bushes and the rubber cushions.............121 8.7 Installing the spindle assembly............................................................123 8.8 Adjusting the proximity switch .............................................................124 2325-9001-020 / 0806 104 Westfalia Separator AG 8.1 Drive All work on the drive may only be carried out by specialists authorized by Westfalia Separator. Before carrying out maintenance or repair work on the motor, bear in mind that there may still be residual voltage. For this purpose, – read the operating instructions given by the manufacturer of the frequency converter, Caution – have the appropriate measures taken by specially trained staff. Fig. 103 During all work on the drive, disconnect the power to the separator and secure against re-starting! Replace damaged gaskets immediately! Caution Before removing separator parts, their fitting position must be marked. This eliminates later problems caused by fitting the part in the wrong position. Before fitting, the grease must be removed from all contact surfaces of the slide- ring packings. Since slide-ring packings are easily destructible, they may only be fitted by specially trained personnel. Attention! Safety risks can arise from the use of non-genuine spare parts. In addition, the durability of such parts is frequently significantly lower which leads to a higher maintenance requirement and lower availability! Therefore, only genuine original spare parts may be used! Attention! 2325-9001-020 / 0806 Westfalia Separator AG 105 8.1.1 Special risks of a separator The separator is equipped with a high-speed rotating metal bowl which repre- sents a danger potential not to be underestimated on account of the rotational energy which can pose a danger for the installation and persons working in the installation when not properly handled. Switch off the separator before carrying out maintenance or repair work. Wait, observe and check that all rotating parts are at a standstill. Do not reach into the rotating drive section or bowl! Do not loosen any part before the bowl has come to a standstill! CAUTION! Risk of injury and danger to life through rotating parts. Standstill should not be checked using only one source of information (e.g. speed indicator) but must be backed up by at least one further checking device. It must always be reckoned with that the first used standstill indication will pro- vide false information because, for example, the electronics have failed or the belt or gearbox in the drive is defective. The following options are available for checking standstill on separators depend- ing on the version: Electric speed indicator Revolution indicator or sight glass on the gear cover of gear separators Optical speed check of the drive motor Noise check Vibration check If you are not sure whether the machine is at a standstill, you must wait for the run-down time specified in the separator documentation. A subsequent check is carried out when you are sure that the machine is at a standstill. Visual speed check by opening the inspection ports on hood and frame Removing the inspection port in the separator hood enables you to look directly on to the bowl. In addition, checking is also possible by removing the gearbox cover or opening the port in the frame. Only when you are convinced that the separator is at a standstill can the following checks be carried out for additional security. NOTE 2325-9001-020 / 0806 106 Westfalia Separator AG Revolution visual check on ma- chines with belt drive. You can observe whether the machine is at a standstill at the points marked with the arrows. We reserve the right to carry out de- sign modifications. Fig. 104 Revolution visual check on ma- chines with gearbox. You can observe whether the machine is at a standstill at the points marked with the arrows. We reserve the right to carry out de- sign modifications. Fig. 105 Revolution visual check on ma- chines with direct drive. You can observe whether the machine is at a standstill at the points marked with the arrows. We reserve the right to carry out de- sign modifications. Fig. 106 2325-9001-020 / 0806 Westfalia Separator AG 107 Observing the motor fan is not a reliable method of checking standstill because the motor or fan can already be at a standstill when the separator bowl is still rotating. NOTE During cleaning programs (steam sterilization and CIP), very high temperatures are reached on the surfaces of the separator and piping. During cleaning programs, the surfaces of the separator and pipes are very hot. CAUTION! Danger of burns! With some products, the separator has to be cooled. As a result, temperatures of up to minus 30 °C are reached on the surfaces of the separator and pipes. When the cooling is switched on, the surfaces of the separator and pipes can get very cold. CAUTION! Danger of frostbite! Depending on type and installation site, hazards in the form of noise emission from the separator may occur. Therefore, always wear protective gear in accordance with the national regulations. CAUTION! Danger of hearing damage! During all maintenance and repair work on the separator, the fittings and pipelines, there is the risk of injury due to spurting liquids, e.g. hot or caustic liquids can spurt out under pressure. CAUTION! Danger of causticization of skin and eyes! 2325-9001-020 / 0806 108 Westfalia Separator AG 8.1.2 Safety precautions for maintenance and repair Observing the maintenance intervals and user information is decisive for the service life and permanent operating readiness of the separator. The maintenance intervals depend on the operating conditions. Especially highly stressed parts of the separator must be regularly checked. Reduce the maintenance intervals to adapt to the operating conditions! Timely maintenance of the separator is essential for safe operation. Especially highly stressed parts of the separator such as – Bowl lock ring, – Bowl bottom, – Bowl top must be regularly checked (at least once a year) as specified in the main- tenance schedule to assure safe and efficient operation. Fig. 107 When carrying out maintenance and repair work: Do not climb onto or stand on the machine or parts of the machine! Danger of injury through slipping or falling down! Fig. 108 Repairs to the separator may only be carried out by service technicians from Westfalia Separator or personnel trained and certified by Westfalia Separator. 2325-9001-020 / 0806 Westfalia Separator AG 109 During maintenance and repair work, make sure that the main switches are switched off and se- cured against restarting. Make sure that other persons do not have the possibility to start the ma- chine before the maintenance or re- pair work is finished. Fig. 109 Make sure that the rotating parts of the separator (drive, bowl) are at a stand- still before carrying out maintenance and repair work. When the machine is defective, a warning sign must be attached and the separator must be secured against unauthorized starting. Do not heat bowl parts with a naked flame to facilitate disman- tling work. Structural changes in the material of the bowl parts which affect the operat- ing safety of the machine may result! Do not weld bowl parts. Fig. 110 Do not weld hood and solids catcher parts of steam-sterilizable separators. 2325-9001-020 / 0806 110 Westfalia Separator AG Place the dismantled separator parts on suitable surfaces (rubber, wood etc.). Take appropriate steps to prevent machine parts from overturning and rolling away. Fig. 111 When carrying out assembly work on several separators, be careful not to interchange parts of different bowls! Each bowl must be balanced with its respective components. The parts are marked with the serial- number of the machine or with the last three digits of the serial number. Fig. 112 Some bowl parts must be arranged in fixed positions relative to one an- other. Locking devices and alignment marks must be in perfect condition. The separator may not be operated when locking devices and marks on the bowl parts are damaged. Fig. 113 2325-9001-020 / 0806 Westfalia Separator AG 111 After fitting certain new bowl parts (e.g. bowl bottom, bowl top) the bowl must be re-balanced. Bowl balancing may be carried out only by specialists from Westfalia Separator or specialist workshops authorized by Westfalia Separator! If in doubt, consult the service de- partment of Westfalia Separator. Fig. 114 Unqualified balancing can lead to dangerous operating states and to de- struction of the separator with danger to life and limb of the personnel. CAUTION! Do not manipulate speed-altering devices such as frequency converters so that the maximum admissible bowl speed (see nameplate or “technical data” in the instruction manual) is not exceeded. Ensure that monitoring devices (e.g. overspeed monitors etc.) are not ma- nipulated or damaged and check their function in accordance with the instruc- tions in chapter “Maintenance and repair – maintenance schedule”. After maintenance and repair work on the separator, refit all protective de- vices. When carrying out maintenance and repair work, carry out a visual check of the separator components. Have the components checked for damage through corrosion and erosion by authorized specialists and proceed in accordance with the instructions in chapter “Maintenance and repair – in- spections”. 2325-9001-020 / 0806 112 Westfalia Separator AG 8.2 Fitting and removing the motor Danger of injury through running machine! Before carrying out work on drive and drive components: – Set the main switch of the separator to "OFF”. – Disconnect power to the motor control and – secure both against switching back on! Caution 8.2.1 Removing the motor Take adequate measures to prevent the motor from overturning. Support it with a hoist (e.g. using a fork stacker and a pallet as shown in figure). The fan housing is designed to hold this type of load. Unscrew hexagon nuts 1. Carefully let the motor touch down with the hoist. Fig. 115 2325-9001-020 / 0806 Westfalia Separator AG 113 8.2.2 Installing the motor Slip clutch element 1 onto the motor shaft as described in the manual for the clutch. Adjust the axial clearance S (gap dimension); refer to the manual for the clutch. Locate the clutch on the motor shaft by means of the adjusting screw. Tighten screws of the clutch with torque (greased screws) M = 37 Nm. Fig. 116 Take adequate measures to prevent the motor from overturning. Lift it with a hoist (e.g. using a fork stacker and a pallet as shown in fig- ure). Turn the clutch elements so that the clutch ring (cam element) catches into clutch element 1 (see Fig. 116 ). Lift the motor with the aid of the hoist. Make sure that the bolts for fastening the motor catch into the holes of the motor flange. Screw on hexagon nuts 1 with in- serted lock washer and tighten firmly. Check width of gap (see Fig. 116 ) and adjust if necessary. For this purpose remove the motor as de- scribed under “Removing the mo- tor”. Fig. 117 2325-9001-020 / 0806 114 Westfalia Separator AG 8.3 Removing spindle assembly, supporting disk Removing the spindle assembly Pull ring 1 with gasket by hand up- wards off the spindle. Remove cap nuts 2 with inserted gaskets. Lift out protective cover 3. Disconnect hose connection 5 for the spraying device. Fig. 118 If the solids catcher has to be dis- mantled: Unscrew the screws for fastening the solids catcher. Screw the eye bolts 1 into the solids catcher. Lift off solids collector 2 together with the chains. Fig. 119 Disconnect hoses 1 and 2 from the connections. Loosen connector 3 of the connect- ing cable towards the proximity switch. The proximity switch can be left in position. Loosen the coupling nut 4 of the bearing condition monitoring system (optional). Fig. 120 Remove hex head screws 1 (fasten- ing rubber-metal bush) and hex head screw 2 (fastening rubber cushion). Thread hex head screws 3 (M12x90) into the four puller holes of the bearing housing and force off the bearing housing by altenately tightening the screws. Fig. 121 2325-9001-020 / 0806 Westfalia Separator AG 115 Screw spindle lifter 1 into the threaded hole of spindle 2 and lift out the spindle unit. Fig. 122 Remove hex head screws 1 from the supporting disk. Thread 4 hex head screws into the tapholes and force the supporting disk from the frame. Fig. 123 Screw in 4 eye bolts 1 and lift off the supporting disk with the hoist. Fig. 124 2325-9001-020 / 0806 116 Westfalia Separator AG 8.4 Dismantling the spindle assembly Undo Allen screws 1 on the oil col- lector housing and lift off cover 3 and clutch ring 2. Fig. 125 Remove securing ring 1. Pull the oil collector housing 2 off the spindle with the tool provided. While doing so, slightly tilt the oil collector housing because of the protruding oil centripetal pump. Fig. 126 Dismantle feather key. Unscrew cylindrical screws 1 and cams 2 (oil centripetal pump). Fig. 127 Unscrew threaded pin 1. Pull off sleeve 2 upwards. Remove the gasket from the sleeve. Fig. 128 2325-9001-020 / 0806 Westfalia Separator AG 117 Unscrew Allen screws 1. Screw two hex head screws 2 into the tapholes of the housing 3. Force off housing 3 by evenly tight- ening the hex head screws 2. Fig. 129 Carefully drive out the spindle to- gether with the bearings by hitting with a hammer. Place a wooden block against the shaft collar at the bottom of the spindle. Drive out the spindle until the angu- lar contact ball bearings have be- come dislodged from their seats. Remove the spindle. Fig. 130 Mount pressure disk to protect the spindle 1. Pull cylindrical roller bearing 2, dis- tance sleeve 3, angular contact ball bearing 4 and oil guide ring 5 off the spindle using a commercially avail- able puller. Fig. 131 2325-9001-020 / 0806 118 Westfalia Separator AG 8.5 Assembling the spindle unit Each time before installing the bearings, make sure: Use only bearings as specified in the Parts List. Replace angular contact ball bearings and grooved ball bearings when they show the slightest sign of damage, but at the latest in accordance with the operating hours specified in the maintenance schedule . The two angular contact ball bearings must always be replaced together. Faulty mounting will inevitably result in irreparable damage to the bearing! Attention! The angular contact ball bearings may be loaded in one direction only. Install the bearings as shown in Fig. 132 . Prepare the spindle: Clean holes. Slip in oil guide ring 1 as far as it will go. Warm up angular contact ball bear- ing 2 in oil to about 80 °C and slip it on the spindle. Watch for correct position! Slip on the distance sleeve 3. Warm up grooved ball bearing 4 in oil to about 80 °C and slip it on the spindle. Insert gasket 5. Insert key 6. Fig. 132 2325-9001-020 / 0806 Westfalia Separator AG 119 Carefully fit spindle 1 with bearing as far as it will go into bearing hous- ing 2. Mount cam 3 (oil centripetal pump) on the bearing housing with cylindri- cal screws 4. Fig. 133 Insert gasket 1 in housing 2. Install housing 2 and fasten with Allen screws 3. Fig. 134 Insert gasket 2 in sleeve 1. Mount sleeve 1. The bore of the sleeve must be placed above the ar- resting hole of the spindle. Fasten sleeve 1 with Allen screws 3 and secure with Loctite 245. Fig. 135 For installation, adjusting or maintenance work on the clutch, refer to the instructions given in the clutch manual. Instruction manual Before mounting the oil collector housing, oil the spindle seat and wipe clean and dry using a cloth. Clean the inner bore of the oil collector housing to ensure a good fit. NOTE 2325-9001-020 / 0806 120 Westfalia Separator AG Slip on the oil collector housing. While doing so, slightly tilt the oil collector housing because of the protruding oil centripetal pump. Install the oil collector housing to- gether with the securing ring. Fig. 136 Fasten clutch ring 2 and ring 3 on the oil collector housing with Allen screws 1. (Torque 37 Nm) Fig. 137 2325-9001-020 / 0806 Westfalia Separator AG 121 8.6 Replacing the rubber-metal bushes and the rubber cushions Removing the rubber-metal bushes: Place bolt 1 on ring 2. Press of rubber-metal bush 3 to- gether with bolt 5 out of the support- ing disk. Fig. 138 With the aid of puller withdraw rub- ber-metal bush over ring 4. Fig. 139 Apply tube pliers only at the lower metal support of the rubber cushion. Remove rubber cushions 1. Fig. 140 Replace vibration absorbers. Insert ring 1. Place bolt 2 on the outer ring of the rubber-metal bush. Press rubber-metal bush 3 into the supporting disk. Fig. 141 2325-9001-020 / 0806 122 Westfalia Separator AG Place ring 1 on bolt 3. Insert disc 2 between inner ring of the rubber-metal bush and the base. Press bolt 3 with bolt 4 into the rub- ber metal bush. Fig. 142 Apply tube pliers only at the lower metal support of the rubber cushion! Install rubber cushions 1 with the tube pliers. Fig. 143 Screw eye bolts 1 into the support- ing disc. Insert supporting disc into the frame using the hoist. Remove eye bolts 1 from the sup- porting disk. Fig. 144 Fasten the supporting disk in the frame with hex head screws 1. Fig. 145 2325-9001-020 / 0806 Westfalia Separator AG 123 8.7 Installing the spindle assembly Screw spindle lifter 1 into the spin- dle. Install spindle assembly 2 in the lower part of the frame with a suit- able hoist. Unscrew spindle lifter 1. Fig. 146 Fasten the spindle assembly to the rubber metal bushes with Allen screws 1 and to the rubber cushions with Allen screws 2. Connect hoses 3 to the respective connections. Insert connector 4 of the connecting cable into the proximity switch (op- tional). Connect vibration pickup 5 (op- tional) for the bearing condition monitoring system. Fig. 147 Place the operating water feeding 3 device 2 on the spindle. Pay atten- tion to correct positioning. Screw in and tighten hex head screws 1. Introduce and screw tight the hoses for the operating water feeding de- vice 2 at the connections 3. Fig. 148 Screw the eye bolts 1 into the solids catcher. Place solids catcher 2 on the frame. Fasten to the frame using the hex head screws. Fig. 149 2325-9001-020 / 0806 124 Westfalia Separator AG Mount protective hood 7 and fasten with cap nuts 1 and hex head screws 3 with gaskets 2 and 4. Fit ring 6 with gasket and fasten with hex head screws 5. Slide the clutch onto the spindle from below and secure against slip- ping with the retaining ring. Fig. 150 8.8 Adjusting the proximity switch If necessary, adjust switching dis- tance A 1 mm ± 0.2 as follows: Screw the proximity switch 1 (M 14x1) as far as it will go onto spindle cap 2, then screw back by a com- plete turn and lock with a hexagon nut. This ensures the correct switch- ing distance. Fig. 151 2325-9001-020 / 0806 Westfalia Separator AG 125 9 Trouble shooting 9.1 Mechanical function .............................................................................126 9.2 Clarifying function ................................................................................130 2325-9001-020 / 0806 126 Westfalia Separator AG 9.1 Mechanical function Fault Possible causes Remedies The bowl does not come up to Motor is incorrectly connected. Check connection rated speed or takes too long to do so (see chapter "Motor con- nection"). Water brake in operation Check brake water valve. The frame drain is blocked. Check the operating water discharge, Liquid or dirt has accumulated in the liquid must run off freely. Clean the frame pot, thereby braking the bowl. frame beneath the bowl. Clutch ring defective or insufficiently Replace clutch ring or check its fas- fastened. tening arrangement. Oil collector housing slides on the Check fastening of oil collector hous- spindle. ing (see chapter “Drive”). Product feed is open. Close product feed. The bowl speed drops during Motor speed drops during operation. Check motor and line voltage. operation. Bowl leaks (current consumption is Check the gaskets in the sliding pis- too high). ton, bowl top and bowl bottom. Clutch defective. Replace the clutch ring (see chapter “Drive”, section “Removing the motor” and “Assembling the spindle unit”). Main bowl gasket in bowl top is Replace gasket (see 4.6). damaged. 2325-9001-020 / 0806 Westfalia Separator AG 127 Fault Possible causes Remedies Uneven run of the separator. Bowl is out of balance. For pos. 1 - 4: Stop the separator immediately. Open the water feed. The bowl may not be emptied as other- wise the vibrations occurring during run- down would intensify. Causes: 1. Solids have deposited unevenly in the bowl and are partially not ejected because D solids structure is too firm, D solids are fibrous or Clean the bowl (4.7). contain coarse impuri- Pre-strain the product. ties, D solids are earthy or sandy or cake together, D Ejection intervals are Readjust on control unit. too long. Shorter ejection intervals. 2. Bowl is not correctly as- Assemble bowl properly (see chapter sembled or parts of differ- 4.4). ent bowls have been inter- changed. 3. Tension of disc stack has Make sure bowl lock ring is screwed on slackened. tightly (see 4.4). A loose lock ring can endanger life. Check number of disks. If necessary, add spare disk or compensating disk. 4. The bowl is damaged and, Send the bowl to the factory for repair. therefore, out of balance. Do not make your own repairs. Do not weld or solder as this would weaken the bowl material – danger to life! 2325-9001-020 / 0806 128 Westfalia Separator AG Fault Possible causes Remedies Uneven run of the separator. Rubber-metal cushions in drive Change the rubber-metal cush- (Cont’d) are fatigued. ions (see chapter “Drive“). Rubber-metal cushions in drive Replace rubber-metal cushions are fatigued. (see chapter “Drive”). Angular contact ball bearings or Replace damaged bearings. cylindrical roller bearings are CAUTION: worn. Use only bearings as specified in the Parts List. Angular contact ball bearings or Replace damaged bearings. cylindrical roller bearings are Clean the lubrication system damaged due to inadequate (see chapter “Cleaning”) lubrication because the suction pipe in the spindle is clogged. Discharging operating water is The ejected solids are too con- Perform several successive total dirty. centrated with the result that ejections manually on the con- they cannot discharge from the trol unit to flush free the solids solids catcher into the discharge catcher. Shorten the ejection pipe. intervals. Solids rise in the catcher and Increase the ejection volume. flow over into the frame to the operating water discharge. Current consumption too high. Bowl leaks. Check the gaskets in the bowl top, sliding piston and bowl bot- tom. Solenoid valve for closing water Check solenoid valve. defective. Oil monitoring alarm Oil level is too low. Top up oil. Lube oil bores of spindle as- Remove the spindle assembly sembly or hoses clogged or (see chapter “Drive”), clean the defective. holes in the drive spindle and hoses. Check hoses for leakage and replace, if necessary. Oil filter clogged. Check the lubricating oil unit and clean according to the instruc- tions in the instruction manual. 2325-9001-020 / 0806 Westfalia Separator AG 129 Note Notes Notizen Anotaciones Notizen Notes Note 2325-9001-020 / 0806 130 Westfalia Separator AG 9.2 Clarifying function Fig. 152 1 Sliding piston A Solenoid valve filling water 2 Closing chamber B Solenoid valve closing water 3 Bowl valve C Solenoid valve hood flush water 4 Bowl bottom D Solenoid valve opening water 5 Gasket (sliding piston) E Metering device 6 Gasket (bowl top) F Non-return valve 7 Main bowl gasket G Water pressure reducer 8 Sealing rim (sliding piston) M Pressure gauge (opening water) 10 Gaskets (bowl bottom) N Pressure gauge closing water 11 Operating water feeding device 12 Gasket (operating water) 2325-9001-020 / 0806 Westfalia Separator AG 131 Fault Possible causes Remedies Ejected solids contain too much Ejection volume too large. Reduce ejection volume. process liquid. Bowl leaks. See following sections. The bowl does not close. Not enough operating water is supplied because CAUTION: Water pressure in the line to the Check line pressure. operating water connection is In this case close the product too low. feed and interrupt the separation The pressure with open valves program. must be min. 2 bar. Water discharge holes in top of Clean holes. operating water feed are par- tially blocked by scale. Strainer in water pressure re- Clean strainer. ducer G of operating–water line is clogged. Operating water feed 11 is leak- Check lines, screw couplings ing. and gaskets. Operating–water feeding system Clean operating–water feeding 11 is blocked. system. Gasket 12 is damaged or has Replace damaged gasket or fit not been inserted. gasket. Gaskets or gasket in bowl Remove valves (see 4.7). Re- valves 3 defective. place damaged gaskets or gas- ket. Gasket 5 in the sliding piston is Replace damaged gasket. damaged or it is frayed at the edges (due to the up and down motion of the piston). If only the edges of the gasket are frayed and the gasket is otherwise in good condition, grind off the edges on an emery wheel and re–use it. 2325-9001-020 / 0806 132 Westfalia Separator AG Fig. 153 1 Sliding piston A Solenoid valve filling water 2 Closing chamber B Solenoid valve closing water 3 Bowl valve C Solenoid valve hood flush water 4 Bowl bottom D Solenoid valve opening water 5 Gasket (sliding piston) E Metering device 6 Gasket (bowl top) F Non-return valve 7 Main bowl gasket G Water pressure reducer 8 Sealing rim (sliding piston) M Pressure gauge (opening water) 10 Gaskets (bowl bottom) N Pressure gauge closing water 11 Operating water feeding device 12 Gasket (operating water) 2325-9001-020 / 0806 Westfalia Separator AG 133 Fault Possible causes Remedies The bowl does not close and The gasket 5 has not settled Stretch the gasket if the pre– open properly. against the outer sealing sur- tension faces in the sliding piston. is too high. Lightly grease the groove in the sliding piston before inserting the gasket. Gasket 7 in the bowl top is dam- Replace gasket (see 4.6). aged. Gaskets 10 in the bowl bottom Fit or replace gaskets. have not been fitted or are dam- aged. Gasket 5 in the sliding piston is Fit correctly dimensioned gas- not accurate in height. ket. The differences in height of a gasket must not be more than 0,25 mm. The sealing rim 8 of the sliding Replace sliding piston. piston is damaged. Bowl does not open at all or not Dry dirt or rubber shreds have Clean bowl parts. completely. deposited between the guides of sliding piston 1 and bowl bottom Round off edges of gaskets. 4. Replace damaged gaskets; grease guides with the special lubricating paste. Closing chamber 2 between Remove sliding piston 1 and bowl bottom and sliding piston is clean the closing chamber. dirty. The holes in bowl valves 3 are Remove valves (see 4.7). blocked. Clean holes. No or not enough opening water is fed to the bowl (master pres- sure gauge M does not deflect) for the following reasons: The non–return valve F is dirty Clean or replace the non–return or defective. valve. Solenoid valve A or D is defec- Replace solenoid valve. tive Air pressure for metering device Increase air pressure to 4 bar. E too low. Opening times of the solenoid Check program times on control valves are incorrectly set. unit (see function diagram). 2325-9001-020 / 0806 134 Westfalia Separator AG Fault Possible causes Remedies The bowl opens during separa- Solenoid valve B is defective. Check solenoid valve. tion. No closing water pulses. Check control unit and closing– water valve. Check control unit and closing–water valve. 2325-9001-020 / 0806 Westfalia Separator AG 135 10 Lubrication and maintenance 10.1 Lubrication schedule............................................................................136 10.2 Maintenance schedule.........................................................................137 10.2.1 Guide to ordering spare parts..............................................................138 10.2.2 Use of non-genuine spare parts ..........................................................139 2325-9001-020 / 0806 136 Westfalia Separator AG 10.1 Lubrication schedule Lubricant Lubrication interval Lubricant qty. Lubrication point Lubricant as required apply thin coat All threads, fittings and contact KSB 8 / WSF surfaces as well as manually operated parts like brake bolts, valves, tools etc. Ceramic paste as required apply thin coat Bowl lock ring Güsol-Anti-Seize (If supplied) Lubricant as required apply thin coat Gaskets KSB 8 / WSF Silicon grease as required apply thin coat All EPDM gaskets Paraliq GTE-703 (If applicable) as per manufacturer specs accord. to manufact. Accord. to manufact. Motor bearings on motor nameplate instruct. instruct. Gear oil See maintenance See data sheet With oil pan or external lubricat- see Parts List, schedule ing oil unit depending on design Roller bearing grease as required apply thin coat Neck bearing springs, spring K3K pistons and pressure surface of the clutch shoe backup. (If applicable) Steam turbine oil See maintenance In accordance with Fluid clutch TDL 32 schedule specs in the docu- (If applicable) mentation Use only lubricants tested by Westfalia Separator for use on separators. The use of non-genuine parts leads to: – safety risks, – less durability of these parts, – reduced availability of the separator, NOTE – increased maintenance requirement. In this case, Westfalia Separator shall assume no liability or warranty. 2325-9001-020 / 0806 Westfalia Separator AG 137 10.2 Maintenance schedule after operating hours every OPERATIONS 250 1000 2000 4000 8000 day 3 6 1 2 mont mont year year hs hs s LUBRICATION SCHEDULE Check oil level and circulation. D D Oil change and thorough cleaning of the lube oil vessel (see also D manual of external lubricating oil unit)* D Grease manually-operated parts (brake bolt, valves, etc) D whenever dismantling Grease threads, contact and guide surfaces of bowl parts (quan- whenever dismantling tity approx. 50 g). as per manufacturer specs on Grease motor ball bearings. as per manufacturer specs on motor nameplate motor nameplate MAINTENANCE SCHEDULE Cleaning Refer to manual of lubricat- D Clean the lubricating oil vessel of the external lube oil unit. D ing oil unit. D Clean bowl valves. D Clean outlet bores of operating-water feeding device. D D Remove bowl. D Clean inner walls of frame solids catcher. as required Clean strainer in pressure reducer in operating-water line. as required product–dependent Dismantle and thoroughly clean the bowl. Be sure also to clean product–dependent the bores and chambers of the hydraulic system. Check D Check starting time and rated speed. D D Check bowl gaskets. D Check the gasket grooves for corrosion. D Check spindle bearings. D whenever dismantling Check the flexible coupling packages. whenever dismantling – wear D Bowl inspection. D Check all bowl parts and threads of lock rings for erosion and corrosion. product–dependent Check material between solids ejection ports. product–dependent after each bowl unbalance Check all screwed unions. D Replacement D Replace all gaskets and seals. D D Replace oil filter of low pressure filter. D D Replace ball bearings of spindle. D D Replace rubber-metal cushions and vibration absorbers. D as required Replace the flexible coupling packages. as required as per manufacturer specs on Replace motor bearing. as per manufacturer specs on motor nameplate motor nameplate * Keep to maintenance intervals even if the operating hours have not been reached. 2325-9001-020 / 0806 138 Westfalia Separator AG 10.2.1 Guide to ordering spare parts Rapid and correct supply of spare parts can only be guaranteed if your order includes the following information: Separator model see separator nameplate e.g. MSD 200-01-076 Serial-No. see separator nameplate e.g. 1724-035 Designation see order-specific parts catalogue Part-No. see order-specific parts catalogue The following information is required only when ordering bowl parts: Bowl S/N since it may be different from the serial number of the machine. It can be found on the bowl lock ring, bowl bottom and bowl top. Information only required when ordering spares for pump and pump connec- tion parts.: Type and number of see pump nameplate pump The information must be complete in order to avoid incorrect deliveries. 2325-9001-020 / 0806 Westfalia Separator AG 139 10.2.2 Use of non-genuine spare parts Use only genuine spare parts from Westfalia Separator. The use of non-genuine parts leads to: – safety risks – less durability of these parts – reduced availability of the separator – increased maintenance requirement. Fig. 154 If a safety risk arises, this may have legal consequences for the responsi- ble persons. In this case, Westfalia Separator shall assume no liability or warranty. NOTE 2325-9001-020 / 0806 Westfalia Separator AG Take the Best – Separate the Rest A company of GEA Group Westfalia Separator AG Werner-Habig-Straße 1 D-59302 Oelde (Germany) Tel.: +49 (0) 25 22 / 77-0 Fax: +49 (0) 25 22 / 77-24 88 http://www.westfalia-separator.com/ mailto:
[email protected]